Sheet metal
Brass sheet is one of the most versatile materials used in the craft of making belt fittings, knife sheaths and armour details. If you want to have a go yourself, you need a material that is easy to shape, cut and work with – without needing a metalworking workshop. In this category, you’ll find brass sheet in thicknesses of 0.5 mm, 0.8 mm and 1.0 mm, supplied as handy 200 × 200 mm sheets, tailored to the typical requirements of re-enactors, craftspeople and DIY enthusiasts.
What is brass sheet and what is it used for?
Brass is an alloy of copper and zinc – usually in a ratio of CuZn37, i.e. 63% copper and 37% zinc. This composition gives brass a range of practical properties: it is corrosion-resistant, can be easily cold-formed and bent, takes a superb polish, and can be both soldered and riveted. Compared to steel, brass is significantly softer and can therefore be worked with simpler tools.
A common misconception: brass is not stainless steel. Stainless steel is a steel alloy with a high chromium content, considerably harder and more difficult to work with for hobbyists. Brass, on the other hand, can be cut to size with a good pair of tin snips or a Dremel and shaped using hand tools – making it ideal for DIY projects.
Brass is of interest for re-enactment and historical craftwork for another reason: the CuZn alloy corresponds to historical models from the Middle Ages. Fittings, buckles, decorative elements and scabbard reinforcements were actually made from brass alloys – so anyone aiming for historically accurate results is on the right track with brass sheet. Typical applications in re-enactment and LARP include belt fittings, knife sheath reinforcements, rivets, decorative elements on armour, and decorative parts such as crests or pendants.
Thickness comparison: 0.5 mm, 0.8 mm and 1.0 mm brass sheet
| Thickness | Properties | Typical use |
|---|---|---|
| 0.5 mm | Very easy to bend | Thin decorative sheets, applied embellishments, foil work, backing sheets |
| 0.8 mm | Balanced | Sheath reinforcements, medium-sized fittings, edge trims |
| 1.0 mm | Dimensionally stable | Robust belt fittings, load-bearing decorative elements, plate armour details |
The 0.5 mm sheet can be bent over moulds by hand and is the ideal material for beginners wishing to try their hand at decorative work. The 0.8 mm sheet is the balanced middle ground: sturdy enough for functional fittings, yet still easy to work with using simple tools. The 1.0 mm sheet is suitable for parts that need to withstand mechanical stress – such as belt fittings that are regularly fastened and unfastened.
Note on dimensional accuracy: A production tolerance of ±15% is standard for sheet thicknesses – this corresponds to the standard in metalworking and has no impact on workability for hobbyists.
Working with brass sheet metal correctly: tips for beginners and advanced users
Cutting brass sheet to size works well with 0.5 mm and 0.8 mm thicknesses using sturdy tin snips. For straight cuts, we recommend lever shears or table-top tin snips; free-form cuts can be easily made with a Dremel or a fine-toothed metal saw. With a thickness of 1.0 mm, a little more force is required – tin snips with long handles or a Dremel with a cutting disc are the better choice here.
The edges should be deburred after every cut – this is not an optional step, but essential for safety and for clean-fitting joints. A small flat file or deburring disc is perfectly adequate for finishing the edges of 200 mm sheets.
Bending and shaping: Brass is easily malleable when cold. For even bends, it is advisable to work over a metal rail or a piece of hardwood as a support. Circular shapes can be bent using round rods. The material ‘springs’ back less than steel, which makes shaping easier.
Both riveting and soft soldering are suitable joining techniques. Riveting is the classic historical method and produces a permanent, visible joint – ideal for fittings on leather straps. Soldering is suitable when two brass pieces need to be joined over a large area. No specialist knowledge is required for either technique – a soldering iron with flux and a little practice are sufficient for most hobby projects.
Typical projects using brass sheet in reenactment and LARP
Belt fittings
Trace the shape onto the sheet, cut out with tin snips, deburr the edges and polish. A ruler is sufficient for simple rectangular fittings. For curved shapes, a cardboard template is recommended. Finished fittings are attached to the leather straps with rivets.
Knife sheaths
Brass sheet is ideal for reinforcing the mouthpiece and side straps on leather sheaths. The sheet is bent around the sheath, secured with rivets and, optionally, engraved or stamped. Combined with knife blades and blanks, this creates a complete craft project.
Armour details & decorative elements
Brass decorative elements are often riveted onto plate armour. Edge finishes on leather armour can also be professionally finished with brass strips. For decorative purposes – guild insignia, coat of arms pendants, decorative elements – 0.5 mm sheet metal is ideal, as it can be easily shaped.
Specialist shops rather than DIY stores: why the choice of materials matters in reenactment
In the sheet metal section of DIY stores, you will mainly find galvanised steel or aluminium. Both have their place in historical craftsmanship – but not everywhere: galvanised steel is harder to work with and has no historical evidence for use in delicate fittings; aluminium has an unsuitable appearance and was not used at all in the Middle Ages. Anyone wishing to produce historically accurate fittings will find it hard to do without brass.
The CuZn alloy corresponds to historical models, as documented in archaeological finds from the Early, High and Late Middle Ages. The 200 × 200 mm sheets are deliberately sized to match typical fitting dimensions: a belt fitting rarely requires more than 5 × 5 cm, and a scabbard reinforcement is usually less than 10 cm in length – the format is therefore suitable for most individual projects without significant waste.
Brass sheet in context: Suitable accessories for your craft project
Brass sheet is rarely used on its own – it reveals its true value when combined with other components. For belt projects, it is best to combine the sheet with leather straps for medieval belts made from vegetable-tanned cowhide and matching buckles for belts and bags. Together with rivets and rings from the consumables range, you can craft complete belt fittings from scratch yourself.
For sheath applications, knife blades and blanks are the natural choice – the finished blade needs a suitable sheath, and that requires brass reinforcements for the mouthpiece and tang. Those who wish to focus less on the craftsmanship aspect will find ready-made bag and belt fittings a practical alternative that requires no DIY work.
You’ll also find additional accessories for craft projects in the section on individual parts for bag making, as well as among the hooks, nails and fittings – everything you need for clean, well-finished joints.
How much does brass sheet cost? An overview of prices and pricing factors
- 0.5 mm: approx. €11.76
- 0.8 mm: approx. €15.88
- 1.0 mm: approx. €16.39
- No waste with typical fitting sizes
- Ready to use, no further assembly required
- Ideal for individual projects and initial trials
- Prices per kg or sq m – from approx. €20–40 upwards depending on thickness
- Custom-cut to size, minimum order quantities apply
- High wastage for small projects
- Suitable for larger quantities or series production
- Often only available as raw material, without a hobby context
For individual projects in reenactment or LARP, the handy small formats are the best value: the price per sheet is significantly lower than that of an industrial cutting order with shipping and processing fees, and the format is suitable for most fitting work without waste. If you are planning several projects, you can simply combine several sheets in different thicknesses.
Whether you want to make your first belt buckle yourself or reinforce a knife sheath with brass – having the right sheet metal in the correct thickness lays the foundation for a convincing result. Take a look at the available thicknesses and find the brass sheet that suits your project.
Frequently asked questions
Brass sheet is a flat material made from the copper-zinc alloy CuZn, characterised by good cold formability, corrosion resistance and an attractive appearance. In re-enactment and LARP, it is primarily used for belt fittings, knife sheaths, rivets and decorative elements on armour. Brass corresponds to historical models from the Middle Ages and is therefore the right choice of material for authentic craftsmanship.
No, brass and stainless steel are fundamentally different materials. Brass is a copper-zinc alloy, gold in colour and relatively soft – it can be cut, bent and riveted using simple tools. Stainless steel is a steel alloy with a high chromium content, significantly harder and more difficult to work with for hobbyists. For historically accurate medieval fittings, brass is the right choice.
For simple decorative fittings without mechanical stress, 0.5 mm is sufficient. The 0.8 mm sheet is the balanced middle ground and is suitable for most standard fittings on belts and scabbards. If you wish to produce robust, dimensionally stable fittings that are subject to regular stress, it is best to use 1.0 mm sheet.
For 0.5 mm and 0.8 mm thicknesses, a sturdy tin snips works well for straight cuts. For free-form cuts and curved shapes, a Dremel with a cutting disc is suitable. For 1.0 mm, a lever shears or a fine metal saw is recommended. After cutting, it is essential to finish the edges with a file or deburring disc – this protects against cuts and ensures clean joints.
In the Vehi-Mercatus range, 200 × 200 mm sheets cost between approx. €11.76 (0.5 mm) and €16.39 (1.0 mm), depending on thickness. For individual projects in the reenactment craft, this small format is good value, as there is no waste and no minimum order quantity is required, unlike with industrial suppliers.