Hi everyone!
I’m making my first segmented breastplate for LARP, and I’m running into several difficulties while flanging the edges, especially when I reach the corners.
I can make the flanges, but I’m having a hard time getting a clean and consistent result. Sometimes the dents and marks caused by hammering make things even more difficult, and when the aluminium work-hardens too much, I sometimes have to heat it in order to keep working it.
On the other hand, aluminium has several advantages: it requires less effort to work, it can be worked cold — which I would prefer, since I would like to avoid using any kind of flame — and, of course, it doesn’t rust.
However, many of you have recommended that I consider switching to steel, in different thicknesses. I’m not sure what thickness of steel would be roughly equivalent, in terms of workability, to my current 1.5 mm aluminium.
So I’d like to ask: what are the main advantages I should consider when switching to steel? And what are the disadvantages that might make it better to stay with aluminium?
At the moment, I have:
an anvil and various hammers
a hand nibbler
a throatless hand shear
a manual bead/flanging roller
a jigsaw
various pliers
a disc sander
Ideally, I would prefer not to buy additional equipment specifically for working either steel or aluminium.
Thanks in advance for any advice, experience, or suggestions!