Padded Chausses: Wish me luck!

[Sir Brian]

I’m going to attempt to make some padded chausses. I of course will be cheating a bit
by using some pre-quilted fabric. I was going to vaguely mimic this guy’s example
with me taking a liberal amount of shortcuts! 
http://www.randyasplund.com/browse/medieval/chauss2.html

Of course Silvermane has some decently priced ones but they are too short
and won't cover my shins where I need them the most. 
http://www.silvermane.com/acatalog/armor_padding.html

I decided to make my padded chausses before I buy these:
http://i221.photobucket.com/albums/dd251/Tah908/Armor/splinted_greaves.jpg
to go with my gorget, bracers and elbow cops.
Bracers & Cops
http://i221.photobucket.com/albums/dd251/Tah908/Armor/splinted_bracer.jpg
http://i221.photobucket.com/albums/dd251/Tah908/Armor/ElbowCop.jpg

I noticed with my bracers that the ends of the rivets has a real potential to dig into my
knee high boots which is not good since I use those boots for several other Renaissance
kits. So, I’ll need something a bit thicker than the thin cotton pants I normally wear,
also something a bit more authentic looking would be nice! 

I will eventually buy these boots to wear with my soon to be purchased greaves.
http://www.medievalcollectibles.com/calf-boots-2708.html

They look authentic enough, have a small heal so my spur straps won’t get trashed and
the price is right @ $60.00!

[Sir Edward]

Of course Silvermane has some decently priced ones but they are too short
and won't cover my shins where I need them the most. 
http://www.silvermane.com/acatalog/armor_padding.html

I just got some of the padded cuisses like those (they're calling them chauses, but I think they're more like cuisses). The black ones with the metal knee aren't actually black. Mine came in natural white like the leather-knee versions. I got both to have a color choice, but instead I just have a knee choice. I'm tempted to try dying them though. At first I didn't think I'd like the steel knees, but now I'm finding them appealing.

Sir Wolf and I looked them over this weekend and found that they have room to spare for both of us, so we thought about removing the leather flaps on the back that lace up, and either stitch them shut permanently or add grommets to lace them up, either way bringing them in by a few inches.

I think your idea of using some pre-quilted material is a good idea! Anything to save on time and money is a good thing. So how do you like the gorget, bracers, and elbows? I'd love to see some pics when you get it all put together!

[Sir Brian]

Well I got one almost done and it is going to work out great. I am very
pleased with the way they turned out. I'll take some photo's at work and
post them later of the various stages of construction. 

I found some scrap pieces of suede leather that I plan to hand sew onto the top
corner for anchor points to my arming belt.

I love my bracers and cops! I plan on ordering the greaves today and
then the boots probably later in the week. Hopefully it will all be delivered
by the end of the month so I can try my completed kit on for a test fitting before
my wife and I go to the GARF on opening weekend on April 12th, so yeah I'll
definately post some picts! 

[Sir Brian]

Thought I’d do a basic step-by-step in case anyone else would like to make their own
Padded Chausses.

Making my Padded Chausses:

Almost all of the material I used. Quilted material from Wal-mart (2 yards @ $4.00 a yd),
White 100% cotton fabric from Wal-mart (same as quilted fabric), poster board for
making a template.
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Material_1.jpg
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Material_2.jpg
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Padded_Fabric.jpg

I measured the circumference of my leg in four locations to get the general widths I
needed and marked them on the poster board, using the straight edge of the board as the
reference point of where the fold will be on the legging.
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Template_01.jpg
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Template_02.jpg
(*Note that these leggings will have only one seam on the outside part of the leg.*)

I drew the basic outline of the outside half of the legging and cut that out. Then I used the
first part of the template on the other side of the board and cut that out, essentially making
two halves which I taped together to mark the outline onto both fabrics allowing
an extra half inch all around the template then cut out two sections of each fabric type.
http://i221.photobucket.com/albums/dd251/Tah908/WIP/insideview.jpg

I made the white inner liner a little bigger to ensure it would adequately cover the quilted
fabric. I pinned the quilted and liner fabrics together then stitched them together approx.
¼” from the edge.
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Stitch_layer_01.jpg
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Stitch_layer_02.jpg

I rechecked the sizing and marked the needed alterations for the correct length and the
angled section needed for the crotch, then stitched those lines on the inner liner side, then
cut off all the excess material all around, allowing an extra ¼ - ½” for the hem seams.
I stitched the top and bottom hems and made the final test fit before stitching the legging
together.
http://i221.photobucket.com/albums/dd251/Tah908/WIP/Inside_Out.jpg
http://i221.photobucket.com/albums/dd251/Tah908/WIP/NearlyDone.jpg

I used 2 – 2” suede leather pieces on each legging for anchor points. I stitched the half
of the two pieces together then stitched them onto the fabric before putting on the brass
grommet. (You have to hand sew the leather so make your life easier by pre-punching the
holes into the leather!)

Here is the finished product!
http://i221.photobucket.com/albums/dd251/Tah908/WIP/PC_001.jpg
http://i221.photobucket.com/albums/dd251/Tah908/WIP/PC_002.jpg

I am really pleased with the way they turned out. I have plenty of room to wear my
padded chausses over a pair of sweat pants if it is cold out yet it is snug and comfortable
enough to wear on my bare legs in the warmer seasons. The belt is the same belt I use to
secure my leg harness to and I was quickly able to modify it for attaching the chausses.

Approximate cost…
In Material: (Fabric, thread, poster board, suede pieces & grommets, etc) = $25.00
In Time: 6 – 8 hours.

So what do you all think?

[Sir Edward]

Nicely done! I found it amazing that your template had almost exactly the sort of stepped contours that my mail chauses ended up with. I didn't start with a template though, I made a diagonal shape, temporarily pinned it together, stuck my leg in, and took note of where I could remove material. A template is much better.

The only difference is the "seam" in the mail with those contours ended up on the inside.

Anyway, it's looking pretty good! It should look great with the new greaves.

[Sir Wolf]

cool, always fun to make things yourself.

[Sir Wolf]

http://www.matuls.pl/index.php?IDP=1&Lng=1&IDKategoria=4&IDPodkategoria=&WyswietlOd=10&Strona=3 here is a version thats out there for sale.