Honor Sash

To create the honor sash, there are several elements required.  Besides the metal mesh, and chain mail, you will require seven bands that cross the sash. They are security guard hat bands, made of silver, or, gold stretch metal. At the bottom of the sash there are three rubber bands which are painted either black, silver, or in Gowron's case, brass.  The klingon symbol and tool, and the buckle, can be made from Fimo.  The metal ends have two oblong buttons or nail heads which are wired to the two buttons of the back section.  The buttons on the front section of the front of the sash, is made with one pyramid shaped brass nail head, mounted on a larger silver colored base.

The mesh is made by Whiting & Davis, Inc. in Attleboro Falls Massachusetts.

It is the same material they used on the original costumes.

The bulk of the sash is an aluminum mesh, #101. The small section that is different is made from an aluminum chain mail they also make.

You have to order at least $100 worth at a time, minimum order. That's about enough for two sashes. It comes in square or rectangular sections, and you have to turn it over, get out your pointy tool of choice and a good light, and open the little spiders and unlink it, then relink it back the length and width you want.(I have a magnifier with an internal lamp which is mounted on a base. Costed $20.00 but have used it a lot with other fine detail finicky stuff.  It makes it much easier to work with the tiny prongs on the back of the mesh.)  You can do that for one sash in about a day. Then you'll have to back it with something, because it sags otherwise.

Problem - #101 - 103 are not produced any more and only small pieces are available for # 103. Their #71 brass mesh(either bias or straight cut) could suffice, but is not cheap. At least the #13 chain mail is still available.

You still have to phone them direct to request a catalog or place an order. Suggest you talk to Lelia Teixeira at phone # (508)699-4412 extension #129. She is willing to work with you and WILL return phone calls.

Unfortunate. #101 is what was used on the show for most of the sash. Be aware that #71 is a very small mesh; each piece is literally the size of a BB. You'll go blind trying to take that apart and piece it together.  If they still have #91 that is the next best thing to use; it is similar to #101 but a little larger mesh.

You can see most of the details of the front of a standard sash.

Back of sash is plain.

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