Ever wanted to craft your own armor, but didn’t know where to begin? Welcome to your starting point. Here, you’ll learn everything you ever needed to know from a real life blacksmith.

Watch as Master Smith, Tony Swatton, owner and founder of Sword & Stone in Burbank, takes you through each metal-forming step of recreating a 16th century closed helmet. You’ve seen much of his armor in films and television, including Captain Hook's hook and Jack Sparrow's sword and now he’s teaching his skills to you.

Advanced Level

2h 15m of duration

Fabrication

English (auto), Spanish (auto)

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Curriculum

1. Title - 16s

2. Introduction - 5min

3. Outlining a Pattern - 7min

4. Cutting Out the Right and Left Sides of the Helmet - 2min

5. Deburring the Edges - 2min

6. Hand Tools - 2min

7. Forming Machine - 5min

8. Refining the Comb of the Helmet - 4min

9. Smoothing the Surface: Pneumatic Planishing Hammer - 2min

10. Shape Refining of the Left/Right Helmet Halves - 3min

11. Welding Together the Two Helmet Halves - 6min

12. Planishing After the Weld - 6min

13. Shaping the Back of the Neck - 3min

14. Refining the Edge - 4min

15. Forming the Bevor - 3min

16. Refining & Planishing the Bevor - 3min

17. Planishing the Bevor: Pneumatic Hammer - 54s

18. Planishing the Bevor: Hand Tools - 1min

19. Reshaping the Bevor Center Line - 2min

20. Shaping & Placing the First Lame of the Neck Piece - 7min

21. Patterning & Placing the Second Lame - 4min

22. Rolling the Bottom Edge of the Second Lame - 2min

23. Roping on the Lower Lame - 3min

24. Patterning, Cutting & Positioning the Ventail - 5min

25. Mounting the Bevor to the Helmet - 2min

26. Patterning & Cutting Out the Visor - 3min

27. Patterning & Cutting Out the Rear Neck Lames - 6min

28. Test Fitting, Trimming & Gauging Alignment - 3min

29. Visor Screws - 47s

30. Rolling the Ventail & Rear Neck Lames - 2min

31. Roping the Rear Neck Lames & Ventail - 2min

32. Fitting the Visor Screws - 2min

33. Stretching & Forming the Visor - 4min

34. Refining the Visor - 12min

35. Hammering in the Ocularium & Riviting the Neck Lames - 6min

36. Sanding & Polishing the Visor - 3min

37. Cutting Out Slits for the Ocularium - 3min

38. Buffing the Visor - 55s

39. Etching on the Comb - 1min

40. Final Assembly - 3min

41. Wrap Up - 56s

Materials

This lesson was shot in a fully functional forge. We are unable to provide links to the materials used.

You will have to do your best!

FOR YOUR WORK STATION

Anvil

Ball Anvil Stake

Belt Grinder w/120 Grit Aluminum Oxide Belt

Crescent Shaped Anvil Stake

Kick Shrinker

Large Polishing Wheel

Pneumatic Planishing Hammer

PullMax Universal Sheet Metal Farming Machine

Throatless Shear

Welding Visor

Work Gloves

TOOLS

Bits and Indexes

Dremel Saw Wheel Bit

Polishing Wheel Bit

Cutting Tools

Dremel

Scissors

Tin Snips/Metal Shears

Hammers

Ball-Peen Hammers (Various Sizes)

Delron Plastic Mallet

Mallet

Single Faced Raising Hammer

Power Tools

Cordless Drill

Punch and Press Tools

Chisel

Cleko Pliers

Rivet Press

Roper Whitney Punch

Tap & Tap Wrench

Wheel Punch

Torches, Solder and Accessories

Aluminum Welding Rods

Arc Welding Torch

Other Tools

Leather Sandbag

Wooden Stump

SUPPLIES

14 Gauge .080 6061-0 Temper Aluminum Sheet

3/8” Screws

Aluminum Foil

Aluminum Rounds

Brown Pattern Paper

Clekos

Masking Tape

Sharpie Marker

HEALTH/SAFETY PRECAUTIONS

When working with toxic and/or dangerous materials or tools:

ALWAYS read labels for appropriate use guidelines

ALWAYS wear a high-grade respirator

ALWAYS work in a well-ventilated area

ALWAYS protect your skin

ALWAYS wear eye protection

Artist BiographyTony Swatton

Costumer, Propmaker, Blacksmith - Tony Swatton is the King of Sword & Stone.

See Full Bio

Additional Purchasing Options

Notice: DVDs do not include closed captions.

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