SCALES or kozane

How to make armor using Kozane

Ok we are talking about scales,  This is the hardest part of Japanese armor.  I will warn you that kozane  take more time and practice then you think.   It will also take MUCH more leather and lacing then a plate style.  But the style is worth it if you have the time.  

The kozane can differ in size and shape  from period to period so I am going to give you a brief overview of the styles.   First lets look at the shapes, 

The first is from 15th century it is the simplest form of kozane.  Some things to notice, one there are 2 columns of  holes and the top row only has one hole in it.  The others show different styles used in other armors.  An average size for Kozane is around 1 inch wide by 3 inches tall.

    Ok you have chosen the style of kozane you are going to use.   Lets talk leather,  The leather you want to use should be stiff but have a degree of  flexibility it should not be brittle at all.  A good weight is around 9 to 14 ounce leather.  I am not going to go into lacquering the leather as it is not conducive to health  so choose a side of leather that is the color that you want.  Or dye it as needed if you know how. 

The most difficult part of making kozane is how do I cut out the scales.  Well I am still looking for an easy way.  The easiest way I have found is to make the kozane as simple as possible. So lets take a Kozane that is 1 inch by 3 inches with a 45 deg cut on the top ( see the second scale in the above picture).  Cut a strip of leather 1 inch wide as long as the hide is long.  

Take the strip and cut off 3 inch sections.

Cut off the 45 deg edge.

If you have a drill press: drill out the holes on one scale. Take care on the first one this will be the template for the others.  Now stack a few scales on your drill press, make sure they are all even with the others. Lay your template on the top og the plates. Drill the lowest left hole going threw all of the scales.  Now put a nail in the hole that you just drilled, realign the scales so they are all lined up for the second hole.  Drill the upper right hole, then place a nail in that hole.  The two nails Should hold the scales in place so they don't move around on you. Drill the other holes and you have some kozane! 

If you don't: Meet your friend the hole punch, on the bright side when your done you will have a bone crushing hand shake! 

Now its on to stitching the kozane together!

Below is a simple stitching pattern.  

Questions? Comments? Insults? contact the web master at: Ichiban@wakagashira.com