I wouldn't go for a cast copper-alloy peak under any circumstances. There is no evidence for the Romans using this method for producing peaks and it would not make sense anyway as it would shatter under a sharp blow, rather than acting to deflect the blow and spread the shock over a wider area as it is designed to do.
As to field repairs to damaged equipment, we can only guess, but forged iron is far more likely than cast copper-alloy. To cast copper alloy, although moulds could easily be made from local clay, you would need the ability to heat the metal up in a controlled environment to a high enough temperature to run smoothly as a liquid. This would be very difficult in the field, unless a local bronze workshop was available.
Iron, on the other hand, is far more convenient to work. You only need to heat the metal up enough for it to become malleable (rather than liquid). A basic forge can be created in something as small as a metal dish not much bigger than a fairly normal sized Chinese wok, as you can see local blacksmiths doing in parts of Africa even today. There is the suggestion as well, primarily from Caesar's Bello Gallica, that portable iron working facilities travelled with an army on campaign.
Therefore whilst it is possible that field repairs might look rough or non-standard, I think it is far and away more likely that they would be of forged iron than cast copper-alloy.
On the matter of how my own helmet was made, to return to a point raised earlier, when I visited White Rose Armoury's workshop a few years ago I saw no forge. I am pretty sure that I saw an oxy-acetalene torch though, or something like that anyway.
Crispvs
Who is called \'\'Paul\'\' by no-one other than his wife, parents and brothers. :!: <img src="{SMILIES_PATH}/icon_exclaim.gif" alt=":!:" title="Exclamation" />:!:
Quote:However I would still say no bronze or brass peak for Gallic G or H or it is going to look odd.
Any more odd than the Carnuntum helmet? The Gallic I helmets are essentially copper-alloy versions of the Gallic G, and featured copper alloy peaks or browguards or whatever we are calling them now. Iron would be more more likely, but lets not forget the Romans loved to be bold and eccentric.
As the legions got semi-permanent stations, towns popped up next to them, and certainly forges, even if iron was more likely, brass would not be impossible, especially if it was cannibalized off another damaged helmet
The helmet you refer to was the Gallic D that now is gone due to an RAF bomb in WWII Here are pictures of the copy I made of this helmet as it was originaly and the afterward repair.
[attachment=5670]100_0249Medium.jpg[/attachment]
Sadly here is all that now remains of that Gallic D with ny reproduction being the only true likeness of the original.
[attachment=5672]bowl01Small.jpg[/attachment]
[attachment=5673]cheekp01Small.jpg[/attachment]
The peak reinforce of the original was made of iron and did have an inlay such as I have done, it was alternating yellow bronze and copper segments that go only in one direction from one end of the peak to the other. I can only assume that it represents an olive branch and not a laurel as many others have done with it going both ways from centre.
This can be seen from the front views where the peak is about 12mm wide and has two grooves for the inlay, this thickness of 12mm would make the reinforce very heavy however it is both concave at its top and bottom surfaces.
There are also only two rivets that show on this helmet and these are the ones that hold the peak to the helmet, this indicates that all the other fittings were braised or soldered onto the original as per what you see.
Here is a closer view of the inlay.
[attachment=5678]100_0253Medium.jpg[/attachment]
Brian,
I found this topic because I needed to replace a broken peak reinforce on my Gallic H helmet. So I'm using your method of making it out of a 3/16 in sheet of steel.
In reading this thread you said you never had a forge yet you made these beautiful helmets. how did you make the helmet bowels without a forge? I would think that simply dishing the metal would not render the shape you need.
The bowl used for this helmet was a spun bowl however it was made into a more eliptical shape by hand beating of the bowl, where you mention that you are making a reinforce out of 3/16 that sounds about right and will not only be strong enough but also keep the weight down.
If you go back to page two of this post you will see a type of template I often use to help get the locating lugs for the rivets to hold the reinforce to the bowl.
Thank you for the Information on the helmet as well as the reinforce replace. I used your diagrams to make the cuts. I went by your measurements as far as thickness and width and shape on page 2. I did modify the ends slightly to make the "disks" end up closer to the helmet bowl when twisted. I used both a cardboard pattern as well as used the old reinforce to make sure ti will fit the bowl. Measuring twice and cutting once is really important with this project. I used hot rolled steel, not as hard as cold rolled steel, but it was quite a challenge getting the jig saw through it. I was able to get a 12" x 12" piece of steel for around $15.00. When I cut the steel I kept the blade lubricated to keep it from getting dull and took my time. You are right about lots of filing I'm still working on that. When I finish Ill try and post some pics.
I think you are mistaken on the Gallic J, I have one, the peak reinforcement is steel with a brass edge. It's not solid brass, unless they have changed it recently.
