Date Uploaded: July 12, 2009, 8:03 pm
Last Edited: January 12, 2013, 2:47 pm
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Chain Mail Display Stand
(Wood; Cross Base; Arm-bar)
Article © MAIL User: justus1199
(note to self, need to get a general-display section -- Ed.)
This stand requires quite a bit of woodworking ability. I have written this for those who have no power equipment. The only tools needed to complete this job are a hand saw and a sharp chisel, though a table saw and drill press will make the job much easier. I will post a much simpler version of this stand that almost anyone will be able to accomplish.
I used 4x4 pressure treated lumber for this stand because I often take it with me to events where it is exposed to weather. You could just as easily make it out of any wood.
Safety note! Pressure treated lumber can be hazardous to your health. Follow all the manufacture's recomendations for safe handling. Most importantly, wear a dust mask when cutting.
Also important! New pressure treated lumber, post 2003, has a different chemical consistency than before. Some brands are very corrosive to galvanized metal! Be sure to read the warning labels on the wood you buy.
Step one: I surface planed all the lumber to remove any chips and bring the lumber to a consistent thickness. Feel free to skip this step as it is largely aesthetic.
Step two: Decide how tall you want your stand to be, unless your chain is as tall as you are, your stand doesn't have to be either. I made my stand about 5 feet high so I could make the entire stand out of one 10-foot long board.
Cut the main upright post to length, then decided how wide you want the cross piece to be. Mine is a wide as my shoulders, or about 24 inches. Cut the two base pieces to the same length.
Step Three: The base (pictured above) requires the most work. Stack the two base pieces perpendicular to each other and mark the width of the top piece on the bottom, then flip the two and mark the top. Take a saw and cut down halfway through both pieces. It is important to cut carefully as these pieces need to fit tightly. Once you have cut down half way, take a chisel and cut out the waste in between the two saw cuts. Use the chisel to smooth the bottom of the cut so the pieces fit together nicely.
Once you have the pieces fitting together you will need to chop a mortise down through both of them together. This is not easy, and will require quite a bit of time if you are new to this. It helps to drill out as much of the wood as possible, and then use a chisel to square up the sides. When you are finished it should look like the picture below.
Step Four: It is time to cut a tenon on the bottom of the upright post. Measure the square mortise in the base carefully and transfer the measurement to the bottom of the post. Then continue the lines up the sides of the post as deep as the base is tall. Cut a perpendicular groove around the post at that depth, then cut down vertically from the base of the post. Use a chisel to smooth the sides of the tenon. It is very important that this fit is very snug. Once you have shaped the tenon to fit the mortise, cut down vertically through the center of the tenon with the saw. After you insert the tenon in the mortise, you will drive a wedge into this groove to lock the post into the base. (Wait until you have fit the cross piece before assembling post and base.)
Step five: Using the same technique that you used to fit the base together, attach the cross bar to the top of the post.
Step six: Assemble the post and the base, turn the whole thing upside down, and drive a wedge into the groove you cut into the tenon.
Dress your stand in the finest of Chain mail. You can also add a post and cap to the top of the stand to hold your helmet.
Again, this is a pretty complex woodworking project. I will have a simple version ready soon.
Original URL: http://www.mailleartisans.org/articles/articledisplay.php?key=284