Quote Originally Posted by turpin View Post
...just not sure how to close the chain links cleanly after installing the belt and clasps. What did you do?
I have made lots of chain mail over the years, so, I have a bit of experience working with chain.

Dog chains come in various chain sizes. For a sporran chain, 2mm is the smallest I would even consider. The one I used here is 2.5 mm. 3mm chain is OK, but will take a lot of hand strength to bend and work the links.

To close a chain link cleanly, one must first cut the link cleanly. A sloppy cut will make a link that has sharp edges that will catch and cut. The easiest way to do this (without overly special equipment) is to use a Dremel Tool with a cut-off wheel. There are a couple safety issues here!
- DO NOT try holding the link in one hand while cutting it with the other.
- DO wear eye protection! (the cut-off wheels often break and shatter in to little pieces!)
Use vice grips to hold a single link, then put the vice grips in a bench vice. This way you can use both hands for the cutting process. Cut where the link was welded together.

Next, using two pairs of pliers, grab each side of the cut link and twist it apart. There are special snub nose pliers that makes this easier, but even regular pliers and/or long nose pliers can be used.

Finally, put the new clasp in place and twist and bend the link back into shape. Your goal is to keep bending and twisting until the ends of the link butt together smoothly in all three dimensions. This last step can be a little tricky. If the link is a bit springy, then you have to bend past where you finally want the link to be. For a heavy link a small hammer can be used along with the pliers to gently pound the link into shape.

If this all sounds too hard, get some miniature key rings (3/8" to 1/2" should be about right) and use that to connect the clasp to the chain link.