Part # 3
The Kusadzuri

Pattern :
The number of kusadzuri needed for a given armor will vary depending on the bottom circumference of the armor. To avoid a lot of confusing explanations and irritating math, I've decided on a ‘standard' kusadzuri size of 5" across the top of the top plate, 12.5" long vertically, and 8" across the bottom of the bottom plate. Make as many kusadzuri as will be necessary to cover you.

* With your Do on and closed tightly, use your tape measure to find the circumference of the Do at the bottom edge. Take this number and divide by six. If your number is, for example, 46", then: 46"/ 6 = 7.66

* Since it's hard to make .66 plates, round the number down. This means you need to make seven kusadzuri for your skirt.

* Go to your poster board and draw an 8" X 12.5" rectangle. At the top, mark a point 1.5" in from each corner.

* Draw a line from the two points to the bottom corners. You should now have the shape of a pyramid without a top. Starting at the top, draw a parallel line every two inches.
(SEE DIAGRAM 3-1).

* Repeat the above so that you have two copies of the pattern. The first one will be used for the ODD numbered plates, and the second one will be used for the EVEN numbered plates.

* We'll begin with the odd plates:

* Take your first trapezoid. From the top line of plate #2, measure down 1/2" and draw a line.

* Repeat this with plates # 4 and #6.
(SEE DIAGRAM 3-2)

* Now cut out plates 1, 3, and 5.

* Now the even plates:

* Take your second trapezoid. From the top of plate #3, measure down 1/2" and draw a line.

* Repeat this with plate #5.

(SEE DIAGRAM 3-3)

* Now cut out plates 2, 4, and 6.

The pattern is done.

* With your table saw, cut out long strips 2.5" wide. Cut out one of each pattern piece for the number of kusadzuri you need.

* Edge and melt the pieces. Now you need to decide how many rows of laces you want. Three is the minimum, but five looks nicer. Because each plate in each row has a different top width, you'll need to play with the spacing of the laces, making them a bit wider for each successive plate.

* Mark and drill your plates.

* Make a 2" wide leather belt. The length of the belt should be equal to the circumference of the bottom of the armor, which you measured earlier.

* Lay out all of the "1 plates of the kusadzuri along the belt, leaving about an inch or so between each one.

* Tape the #1 plates to the belt. Wrap the belt around the Do and see if you have full coverage. If not, adjust the plates.

**NOTE-- You should always adjust the kusa-zuri so that one of the rows is centered in the front. Otherwise you'll look silly.**
(Editor's note...Yama Kaminari Samurai are not allowed to look silly - unless we are all looking silly, because our Daimyo ordered it for his ammusement!)

* Once you have the plates adjusted to your liking, mark and punch the belt so you can hard lace the top plates onto it. Now hard lace the plates to the belt, making sure to tie off the laces at the bottom and melt the knots.

* Punch holes in the belt between each kusadzuri. Drill 1/8" holes around the bottom of the Do in the appropriate places and hard-lace the skirt to the bottom of your Do.

(SEE DIAGRAM 3-4)