Except for the rare finds just mentioned, we know little about the armor and arms of the period from the fall of Rome to about the twelfth century. The paintings, drawings, and statues which have survived suggest, but give no clear information. We have reason to believe that armor was made of small plates of iron attached to cloth or leather garments, or of chain mail, a fabric made of interlinked rings of iron wire. Towards the end of this period we know that chain mail was extensively employed, for it often appears, especially in England, on the engraved brass plates attached to the tombs of important people of the time (Fig. 7). The Museum has a small collection of paper impressions of these “brasses” which are well worthy of study by anyone interested in early armor. Some are exhibited on the walls of the armor gallery.

Chain mail is more interesting than it appears at first glance, and the Museum’s specimens deserve to be looked at carefully. In the first place, it was made of wire. Nowadays wire is so common that we think nothing of it; it is produced by the mile with automatic machinery. But in medieval times wire was scarce and valuable, for every bit of it had to be made by hand. At first this was done with the hammer: a billet of iron was pounded with a hammer held in one hand, while the other kept the billet rotating so that its diameter became less and less until it was small enough to be made up into links of mail. Of course, only short bits of wire could be made in this way and the diameter was naturally irregular. It was slow and tedious work, but the earliest mail was so made. Later it was found that a rod of iron could be pulled by tongs through a hole in a hardened steel plate, thus reducing its diameter and giving it a uniform thickness. By drawing it through a number of holes of progressively smaller diameter, the wire could be made quite thin and entirely uniform. Then such wire could be wound in a coil around an iron rod, and the coil then cut lengthwise with a chisel or saw giving a large number of links all of the same size. All later chain mail was so made. Such links were interlaced, each link with four others, to form a fabric much like that of a lady’s mesh bag. However, if the ends of the links were simply brought together the fabric would not be very strong. An arrow or dagger point could easily spread open a link, and penetrate to the wearer’s body. So all good chain mail was strengthened by having the ends of every link overlapped, slightly flattened, and then riveted. In that part of the world we now call “Middle East”—where the Mohammedan and Hindu cultures flourished—the rivet was a separate piece of fine wire. European chain mail is more of a mystery—principally because there is so very little old European chain mail still in existence. The probability is that a separate rivet was used as in the Eastern mail, but that its insertion was more skillfully performed. However, some scholars feel that European chain mail was welded or was riveted by a swaging process, that a special tool in the form of tongs or a pair of dies forced a small part of the lower end of the link of chain mail through a slit in the upper end and then riveted it over. Careful microscopical research on sections of links of mail could doubtless solve this problems, but who wants to cut off links from a rare and precious genuine, documented piece? As yet it may be said that no such ingenious swaging tool has been discovered, nor have we any unquestionably contemporary illustrations which would prove this theory.

In places where special strength was required, as around the throat, the rings were made of the same size but of heavier wire, which was flattened by hammering in the neighborhood of the rivet. In this way the overlapping of the rings became so close that not even a needle could penetrate the fabric (Fig. 8). In other cases, unflattened rings were used, but strands of leather were drawn through the rows, giving additional rigidity and protection. It is believed that this practice accounts for the appearance of what is known as “banded mail” in numerous monuments and engraved brasses.

Chain mail was a good protection against cuts and stabs, but it had a number of serious disadvantages. In the first place, it was expensive. Even the most skillful armorer could make it but slowly. The mail cape of Fig. 8 contains about 44,235 links, each separately forged and riveted; some complete coats of mail contain over 200,000! Forgeries of antique chain mail are practically non-existent, for they would cost more to make than genuine specimens, rare as they are, would be worth today.

Again, chain mail was very easily attacked by rust, and, once it was rusted, was most difficult to clean. (The usual way was to put a rusted mail shirt in a barrel with some oily sawdust and to set an apprentice to rolling the barrel around for hour after hour.) Consequently very little early mail is left—most of it just rusted away to nothing. It was heavy and uncomfortable, for the whole weight hung from the shoulders.

But its worst disadvantage lay in its flexibility. It would resist a cut, but was of little protection against a blow. To make it of any use in battle against heavy swords, maces, and battle axes it was necessary to wear beneath it a very heavily padded garment which, of course, was hot. How the Crusaders in their chain mail must have sweated in the hot sun of the Holy Land! And how many mail-clad knights must have been pounded to death without necessarily losing one drop of blood!