In Japan today there are only a handful of authentic kacchu shi, or artisanal armourers, remaining who still make Japanese helmets and armour. Only those who are truly passionate about their craft have been able to continue this centuries-old tradition.

The repair and reconditioning of an old suit of armour can take up to a year of work, and simpler parts such as some helmets can take one or two months. Making a new suit of armour from scratch, which carefully replicates the ancient styles and features of the Heian, Kamakura or Muromachi periods, can take anything from three to five years.

First, cowhide is dried and cut into about three thousand small plates called kozane which are pierced with about fourteen holes, and then overlapped one by one until the entire armour is covered. They must then be joined together with silk thread in a painstaking process called odoshi. A minimum of three hundred metres of silk cord is usually used to braid a complete suit of armour.

Finally, the armour is decorated with different kinds of motifs such as dragons, dragonflies or plants, one of the most common being the chrysanthemum, which is the the national flower of Japan, and also the Imperial emblem. The armour is finished with a very careful lacquer called urushi, which, in addition to protecting all the pieces, gives them a spectacular aesthetic.

A true craftsman of Japanese armour produces work that is worthy of the highest honours and accolades; and this skill and artistry required by the kacchu shi throughout his life requires the utmost perseverence.

This new book Ninniku Yoroi: The Armour of Perseverance, seeks to provide an introduction to the fascinating world of samurai armour, along with a detailed exploration of the evolution of the design of these distinctive protective suits over the centuries. The Yoroi is examined not only from the perspective of their use in combat, but also as artifacts of artistic beauty and as expressions of power within the warrior Japanese warrior caste.

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