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· wave man TDY staff
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A number of members have made armour from soda can metal. I figure you could use a decent pair of small, curved and straight cuticle scissors to cut like mini-shears.
plump even made armour from putty - http://www.onesixthwarriors.com/for...ays-his-debts-tyrion-lannister-completed.html

There's all manner of small metal punches out there, at hobby, craft, and too supplies. As for rivets, lots of possibilities. I like your soft, small gauge wire idea. Get a small anvil (or even a small piece of thick flat stock from a local metal outfit), and a small hammer. You could even experiment with drilling shallow depressions in the block, which could be used to form the rivet heads.

Hopefully, some of our scale armourers will speak out.

Mike
 
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