Rob MacLennan

Well that eliminates one possibility. There are a couple of options then. The first is to properly taper the shirt so that it better conforms to your body, using expansions and contractions, if you haven't already done so. This will mean there's less material to swing loose. The second might be a little counter intuitive; lengthen it. This won't stop it from swinging loose, but it will alter the location that the swing hits to something less sensitive.

Are you wearing a belt over it?

Well that sucks. I thought that the whole point of paying the extra for UPS Worldwide was that they took care of all the fees.

It's not a question of corrosion. Galvanized steel, like fencing wire, has a zinc coating to make it corrosion resistant. It, and annealed wire, are both rather soft and deform more easily over time (meaning more maintenance) than stronger wires do.

Unfortunately what happened is 6 years. Internet years are like 10X human years. If you check the "Instructions" page on the TRL website you'll see there are a bunch of instructions that are "free with any purchase." https://theringlord.com/cart/shopdisplayproducts.asp?id=199&cat=Downloadable+Chainmail+Patterns+%2B+Instructions

Safe? Yes, modern lead free solder would be safe enough to use, however, the composition of your rings is important. If you're using galvanized steel rings then you don't want to heat them, because you'll end up with the "zinc shakes" from zinc poisoning. Solder won't take on metals like aluminum. You may just find it easier to use stronger metals (spring steel, stainless steel), or larger gauge rings. For example 3/8", 12 gauge aluminum rings look pretty beefy and resist pulling open better, over time, but butted ring mail is just plain going to need maintenance at some point anyway.

1/8" shirt. Now there's dedication. For pieces at that scale I haven't gone below 1/4".

You would think that a mod would know how but after the upgrade, I haven't got a clue. Got to dig into it.

I was roughly 200+ pounds when I originally made the shirt, but have since pared down to 150, which is part of the reason I'll be re-making it. It's made to fit over a cheap LARP gambeson. If I had any attachment space left, I'd post a pic.

I got away with doing that for a couple of parties, several hours long each, without repair in between. Then again I'm 5'9" (174cm.), so the weight may not be anywhere near what you're going to be dealing with. *NOTE* My plan is to eventually convert this piece to using steel rings.

Even with that it might take some judicious sanding of the area to which the wire/bolt is brazed.

If they're the armourer's pliers that I think they are, there's no ready facility to which a ground lug might be attached. You might be able to have someone weld a bolt to it and then use that to attach a cable, but I'm skeptical. There's just not a lot of exposed metal, except for the jaws.

Moved to Discussion so it gets more traffic.

You're looking for expansions/contractions and hole-row expansions/contractions, depending upon in what direction the mail hangs. I tried posting a link to the discussion on that topic, on this board, but it errors out. Try searching for those terms.

A cheap plastic storage box from Target or Wal-Mart would do the trick, plus you'd be giving something to store it in at the same time. In the past I've used boxes from IP phones and Dell replacement parts, because they aren't your typical flimsy shirt box. An 8 pound aluminum chain shirt, with scale upper arm, made it from Toronto to Chicago, with barely a mark on the box.