Repairing a gallic I helmet

[Graff]

I recently picked up a Gallic I helmet but it needs a new reinforcing peak. I was wondering if anyone here has ever attempted to fabricate a replacement peak for any of these helmets and if there is any suggestions on what would be the best way to do this. From pics that I have seen this piece looks to be about 1/8" thick brass. Is this correct?

[M. Demetrius]

Are you talking about the brow ridge?
http://www.lawrensnest.com/images/RHM6352N.jpg
http://www.larp.com/legioxx/GalI4.jpg

If you're working brass, it might be easier to cut and file the piece to fit from a thick plate, rather than try to make the bend. I have had little luck in getting brass to follow that kind of smooth curve, when bending on the thick. Maybe other people have more skill.

[Graff]

It is the brow ridge that I am talking about.

I was thinking that it would be easier to just cut it out of sheet brass of the correct thickness and heating and hammer flattening the ends for the rivets. I had thought that trying to use bar brass and trying to bend it to the correct shape would be difficult. If it could be done easily it would be the cheaper way to go since sheet brass is way more but if it cuts down of frustration and trouble the extra cost would be worth the price.....

[M. Demetrius]

but if it cuts down of frustration and trouble the extra cost would be worth the price.....

100% guaranteed, though all the cutting and smoothing has its own set of issues. And you'll have several large bits of brass that may not be of use to you. No matter how you go about it, you will have two rivets to set, but that's small potatoes compared to the metal shaping.

[Matthew Amt]

I've made a couple brow reinforces from brass bar stock, 1/4" by 3/8". Here's one:

http://www.larp.com/legioxx/CoolC1.jpg

It wasn't really all that hard, though it can certainly be a little tricky and finicky. LOTS cheaper, though!

Never work hot brass! Heat it to a glow and then quench in water to anneal or soften it. Curve it with a rubber/rawhide/plastic mallet over a log or into a sandbag, to avoid gouging the metal with steel tools. I seem to recall just sticking the end into the square hardy hole on my anvil and just leaning on it to start bending it. If you don't have a large heat source, you'll probably have to anneal and work short sections at a time, but that will work. And you will have to anneal repeatedly to get the amount of curve you want in any case. Also be careful about the thing twisting or wanting to bend across the flat rather than along the edge! Like I said, it's tricky...

Once you get the length and curvature right, anneal the HECK out of the ends before flattening them (with steel hammer on an anvil of some sort). And only hammer a little before re-annealing, or the piece will split and be ruined. You don't have to get it *really* flat, anyway, just expanded out enough to be able to drill a 1/8" rivet hole safely.

I also tried to do a brow reinforce out of steel stock, once. But it must have been stainless or something other than mild steel, cuz it did NOT want to bend! Still have a slightly curved piece of scrap stock kicking around my workshop... Brass is easy by comparison! Though with steel you can work it hot, which can be a big advantage.

Good luck!

Matthew

[Graff]

Thanks for the tips and advice....I started on fabricating one today. I will see how it goes. I got to the half way point in a couple of hours of working it but its is not easy to keep the brass from bending to one side or the other when hammering it. I dont know how pretty this first try will come out but I getting some experience with it and Im enjoying learning something new as far as fabrication of stuff goes....Ill post some pics when I get done ....

Mike

[M. Demetrius]

Ill post some pics when I get done

Don't keep us in suspense too long!

[Graff]

Finally after much trial and error I pretty much have the piece done. This is about the best I could do with my limited ability but I think it turned out ok.....

[M. Demetrius]

Skillfully and wonderfully made. Great work!