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Thursday, March 11, 2021

Evolution of Armor: Ancient Egypt to 15th Century

For as long as humans have been fighting themselves, they have been trying to find ways to protect themselves from blows and creating new and powerful ways to kill as many people as efficiently as possible…

Egypt

There were four main types of weapons used by the Egyptians; the spear, the bow, the sword, and the axe. Egypt’s power was mostly during the Bronze Age, and iron was rare and extremely expensive. King Tutankhamen had one small iron dagger, and it was worth many times its weight in gold. The spears used by the ancient Egyptians were quite average. Most of the time they were a leaf-shaped bronze tip mounted on a shaft of what was probably cedar wood from Lebanon. Their axes were not like the axes we think of today, the handles were short with a long heat and a short blade, similar to the tomahawks that would appear much later. Their swords were probably the most iconic piece of their arsenal. Sometimes an Egyptian would carry a hooked sickle sword, called a khopesh. The khopesh was a secondary weapon meant to be used after one had lost his spear or bow. Along with the spear, the bow was widely used by the soldiers of Egypt. In the Old Kingdom, bows were relatively weak and made of a single branch, but by the New Kingdom, Egypt had adopted the compound bow, which was laminated with horn and animal sinew to increase its strength.

Due to the hot climate and ways in which battles were fought, Egyptian armor was all but nonexistent. Nearly all of the body protection of the Egyptians came from their shields. Egyptian shields were one of the earliest forms of tower shields and were made of cowhide stretched over a wood frame. Even this was sometimes abandoned due to it restricting the user on the use of their weapons. Sometimes a shield bearer would protect an archer, similar to how the Egyptians used chariots. However, even the chariots only protected the lower portion of the wearer leaving the upper portion exposed.

Greece

The weapons and armor of Greece show close resemblance as far as function, but the Greeks had two significant improvements; armor and cavalry. While the cavalry was used mostly by the Greeks of the north (such as the Macedonians), armor was used extensively by all Greek Hoplites. The Greek helmet underwent a drastic evolution, though the most iconic is the Corinthian helmet, which features long cheek and nose guards and often a decorative crest. Interestingly, this style of helmet seems to have endured through the ages. A very famous and protective example from the late fifteenth century, known as the Avant Armor, features a style of helmet called a barbute, which bears striking resemblance to the Corinthian helmet.

 

For body protection, Greece used two main types of vest. One is now called an anatomical cuirass. This is the hammered bronze armor, which is often embossed to resemble a muscular chest and appears often in modern cinema. The other type is called a linothorax. The linothorax was made of laminating several sheets of linen together. The linothorax was very popular due to its lightness, breathability, low cost, and comparable protective capability to the bronze breastplate. Sometimes little bronze scales would be sewn to it the increase its protective capability. To complete the set, one could also add beaten bronze greaves and bracers.

Much like the Egyptians, the Greeks relied heavily on the bow and spear. The sword was and always would be a secondary weapon until they fell out of use. Unlike the Egyptians, however, the Greeks learned to put the spear and shield to a better use with an advanced variant of the shield wall. Later the Macedonians would use several rows of soldiers and much longer spears, called pikes, to create a bristling wall of spearheads, called a phalanx. In a technique called the hammer and anvil, the phalanx would attack the middle, while the cavalry swooped in from behind, crushing the enemy on two fronts.

Rome

At Rome’s beginning, it would be very difficult to distinguish between a Greek and Roman soldier. The way they fought and were armed traditionally as hoplites was almost identical. Over time though, units became more specialized. On one hand, heavy infantry began to carry shields that were longer and oval shaped. The bronze breastplate was abandoned for coats of maille, called lorica hamatae, and linen armor became the norm and would remain so for years to come. With a lorica hamata, however, a form of padding was required, called a submaralis. This was an early form of what would eventually become the gambeson. Most of the development in the arsenal of the Roman infantryman was the shield. The shield steadily became more useful for formations, eventually evolving into the iconic tower shield known as the Scutum. The Scutum was suited almost exclusively to formations, and therefore of limited use in a one-on-one conflict.  The smaller oval shaped shield was still used for cavalry; however, unlike the Greeks, cavalry was never widely used. The armor continued to evolve, leading to the creation of a segmented plate armor called lorica segmentata, as well as a more ceremonial scale armor called lorica squamata.

Rome also utilized a lighter form of infantrymen. This soldier would carry a smaller, lighter shield and carry several throwing spears individually, called pilum. A pilum had a barbed head attached to a long metal bar with a weight in the middle. Even if the pilum happened to miss its target, when a pilum struck an enemy shield, it would stick and the soft iron rod would bend, making the shield unusable and leaving the owner defenseless.

To finish arming the Roman infantryman, he would need a helmet, sword, and dagger. The early Roman helmets were very similar to the late era Greek helmets. The tall point they came to eventually turned back into a semicircle, however the hanging cheek guards and flared back remained. With the addition of a rim above the eyes, it became known as a gala helmet. This was the helmet that, over time, would become the spangenhelm, the common ancestor of all medieval helmets.  Neither the Roman gladius, nor the dagger, called a pugio, underwent much evolution, though both were commonly used. Both consisted of a straight piece of sharpened metal, occasionally with a slight leaf shape to them, and were best suited to the stabbing type fighting used in a shield wall.

Byzantium

Byzantium was what remained after Rome’s western portion fell. It retained much of the influence western Rome had on it while also including some ideas from the east and north. For example, the Byzantines, unlike their Roman counterparts, relied heavily on cavalry, and the infantry was kept mostly out of tradition.

Weapons like the Greek xiphos came back into style, and showing influence from the east, a saber like sword became a new addition. Heavier weapons became more common also; long axes and maces began to be used. The renowned Varangian Guard, Norse mercenaries  who served as the emperors personal guard in peace time and Byzantium’s most elite unit during war, were feared for the long two handed axes they used.

While the plate armor of the Romans did not disappear during the time of Byzantium, it did undergo a drastic transformation. While opinions vary on why lorica segmentata fell out of use, it is clear that in Byzantium at least, lorica squamata and variations on its forms rose in popularity. Scales became larger and lamellar cuirasses, small plates of metal laced together with cord, called kilvanions, became popular among the wealthy. Maille, however, was still the primary form of protection, as it could be easily produced despite the extensive time it takes to make it.

Scandinavia

While the Byzantines held power over the south, the Norse sphere of influence was in the north. Following the trend set by the Romans and Byzantines, the Norse used almost entirely maille. Maille garments grew longer and longer, eventually becoming a hauberk, which covers the arms chest and upper legs. For head protection, a Norseman could choose between a helmet and a coif. If they were Vikings, they would often wear whatever happened to be the best thing they stole, and with the extensive colonization by the Norse, these items could be quite varied.

During the so-called Viking Era, weapons became more multi-purpose. Bearded axes that chopped wood were also tools of war. The type of knife known today as the seax, the original form of the modern Bowie, was carried by most as a utility knife and a defensive weapon. Weapons that were purely weapons, like the sword and spear, underwent very little evolution also. With the exception of a change in guard, the Viking age sword looked very similar to the late Roman cavalry spatha and would continue to do so until the late 12th century.

Medieval Europe


 

The medieval era is when armor underwent its most drastic changes and gained a great deal of variety. In the early Middle Ages, maille was used almost exclusively, but gradually as weapons improved, so did armor. It began with the advent of the coat of plates around the 13th century. Coats of plates were similar to the lorica segmentata, but improvements in design and metalworking technology allowed for larger plates and less constriction on the body shape and size of the wearer by riveting them to a sheet of fabric or leather. Plates became larger and smaller, forming the side or front opening versions of  the coat of plates, called brigandines. By the 14th century, a small but solid chest plate, known as a globose, had also evolved. Variation on combining these two armors created a great variety of styles. One form of brigandine, called the Wimbledon type, had a plate pattern that bore a striking resemblance to the lorica segmentata, while other forms like the Chalkis type 1 and Munich type brigandines featured forms of the globose while adding a skirt of plates to increase its protective capabilities.

As body armor improved, so did the armor for helmets and limbs. Greaves, which protected the knees, had a cuisse added which extends up to cover the thigh, as well as adding articulated joints, called polyens, on the knees, and cops on the arms. Pauldrons were added to the shoulders, and the full hauberk or smaller habergeon was often replaced by voiders; supplementary armor used to cover the places armor would restrict movement in.

Helmets grew to increasingly various shapes and sizes. In the 12th century people still used the basic nasal helm like the Vikings. By the 13th century, the crusader style topfhelm and larger greathelm were used, often on top of a cervelliere or bascinet helmet. Even though the great helm was largely abandoned after this century, it was still used in jousting due to its superior protective ability.   A variation known as the frog-mouth helm was used up until he 15th century, and a smaller form known as the sugarloaf helm was still used in combat.


 

The longest, and one of the most balanced helmets, the bascinet, came during the 14th century. This form of the bascinet was longer and covered more of the head than the previous form. It also had a visor that could flip down and cover the wearer’s face. The neck was still protected by a maille or scale aventail, often sewn to a padded liner. There were a variety of options a knight could chose for visors, such as the long pointed houndskull, the flatter more comfortable klappvisor, and some even chose to use only a nasal piece for better breathability and sight.

Weapons and shields underwent a very clear and consistent evolution during the Middle Ages. Steadily, shields grew smaller and smaller, while weapons grew longer and more oriented to thrusting rather than cutting. It started with the arming sword. The arming sword was a direct evolution of the Viking

age sword and similar in use.  Its one handed broad nature made it effective used with a shield, often a classic heater shape. There were some differences though. The pommel was smaller, to allow for more wrist movement, and the guard was larger, offering more protection. With the advent of the coat of plates, the swords steadily became more pointed until the fifteenth century, when most swords were used exclusively for thrusting. Soon the shield was abandoned completely, with knights relying purely on the effectiveness of their armor for protection, and two-handed weapons like the longsword were adopted.  Fourteenth and fifteenth century longswords, like the type XVIa and XVIIIb, were fast, versatile, and very effective about finding gaps in armor, but they required a certain amount of skill to use and they were rather poor at defending against heavier weapons like polearms.

Polearms were primary weapons in a battle, as well as the lance, if a knight was mounted. Men at arms, with very little experience, could effectively wield weapons like a bill or a glaive in a pike type formation or on their own. For people with more training, a six-foot polearm, such as a poleaxe or pole hammer, could smash through an opponent’s armor. The length allowed for the user to generate a lot of leverage and force without slowing down the user or difficulty changing direction. The lance also was an effective first strike weapon. A charge of mounted knights, with 10-foot lance and the force of the horse and the weight of the armor behind it, would easily break through almost any line spread before it.

The most dangerous weapon to this kind of charge though was the bow, as the French learned at the Battle of Crecy. A line of mounted French knights charged the English, only to be met with a rain of arrows and be completely decimated. War arrows, like the ones used then, had an acutely pointed and hard tip that was excellent at either punching through or finding gaps in armor. The bows were most often made of yew, one of the most effective woods for making a bow. The heartwood is very resistant to compression and the sapwood very resistant to tension, giving the force of some of the bows 160 to 200lbs.

Along with a sword, shield, and long weapon of some kind, knights would almost always carry a dagger. There were several options, but a knight would usually choose a rondel, bollock, or quillion dagger.  The medieval armor evolution ended, though, with the introduction of gunpowder. Armor and weapons simply could not stand against the power of a musket barrage. For a while, some weapons like the bardiche and the rapier survived, but soon they too became largely ceremonial or simply worn out of tradition before fading completely. People look down on the past as primitive and unsophisticated, but we must remember the future is built on the past, and the past can never be forgotten.

Citations

·         Dawnson, Timothy George. (2020.)  Armor.  (Leventia site.) https://www.levantia.com.au/byzarmour.html

·         Dawnson, Timothy George. (2020.)  Weapons.  (Leventia site.) https://www.levantia.com.au/byzweapons.html

·         Groeneveld, Emma. (June 1, 2018). Viking Warfare. (Ancient History Encyclopedia site.) https://www.ancient.eu/Viking_Warfare/

·         Williamson, Mitch. (August 14, 2015.) Military of the Byzantines. (Weapons and Warfare site.) https://weaponsandwarfare.com/2015/08/14/the-military-of-the-byzantines/

 


Wednesday, March 3, 2021

Making a Rondel Dagger

This design is based on this 15th century rondel dagger found in the Metropolitan Museum. A close runner up was the a rondel dagger found at the Wallace Collection.
I experimented with the design and made a few small modifications, but given that this dagger is supposed to be functional as well as aesthetically pleasing, I went with a simpler design.
The overall shape was cut with an angle grinder from a lawn mover blade, but still had to be forged to its final shape and heat treated
The bevels were roughly formed with an angle grinder, and steadily sanded using several different grits of sandpaper until I finished it with a piece of 400 grit paper, which gives it a nice satin finish.
The rondels that give the dagger its name are plain carbon steel cut from 14 gauge plate, however I would not recommend anything thinner. I polished them to a 240 grit, but gave them their finish with a wire wheel. The handle is made from the heartwood of red cedar. I drilled a hole all the way through and heated the tang. I then did what is called a burn-through, where the tang burns a hole in the handle to give it a tight fit.
The handle was shaped with a simple belt sander and polished with sandpaper, steel wool, and a scotch-brite pad. I finished it with oil to bring out the deep red color. The rondels were given one last polish with steel wool, and then blued with gun bluing and oiled for the blackened steel look.
For the final assembly, I used two-part epoxy, then cut off the excess tang and peened it down. I blued the peened end of the tang, then gave it one last coat of oil.

I made the sheath out of leather, and did not add a wood core. To do this, I made a wooden blank of the blade. I then soaked the leather and sewed to it around the blank to form it.
After that I died the leather red, but I also used and antiquing gel to get that rich mahogany color, as well as make the small amount of tooling I've added  become more visible. I then added a satin finish to protect and seal the leather.
One problem with rondel daggers is the fact that the center of gravity is in the handle rather than the blade. To help the dagger hang, and protect the end of the leather, I made piece called a chape. I used a rod that I use for forging arrows and hammered a piece of 16 gauge metal around it. A small piece of square stock is welded to the tip and filed decoratively.
The last piece was a throat. It was also a piece of metal wrapped around a form which I then welded a loop to the add a leather cord for attaching to a belt.


Private message received from a reader...
"I see a lot of talent there!  Study of some metallurgy and machining/welding processes are skills that are in huge demand these days.  I don't know if that's what you're interested in but your skills at this age certainly point to that being something you'd enjoy and would be very good at!  Knife and tool making is a very specialized skill that I've always found really interesting.  Design and development of tooling and dies for manufacturing are huge too, on top of the skills to run the machinery (lathes, mills, forges, etc.) to make that stuff."  ~Kevin