Check out The Journal of the Mail Research Society - it's the best single article I've ever read on mail. It'll answer every question you could possibly ask. Though, seeing as you are interested, I think I might make up a mail making tutorials for the new tutorials.livinghistory.ie - I think I could do a decent 3 min video on going from bare wire to the finished product.
Basically, there is a massive difference between butted and riveted mail. Imagine making two fists, and joining them together, knuckle to knuckle, making the strongest link you can. Get your wife to pull your fists apart. Chances are, she can. Now, get her to do the same, only this time have get her to grip each fingers, interlocked. The extra purchase likely means you can't pull her arms apart.
When I make mail at gigs, I make up some links from 0.9mm wire, and some from 0.5mm wire. The 0.9mm butted links look pretty sturdy, until you make a chain - a simple twist breaks them apart. The 0.9mm riveted links can't be broken up without a chisel an hammer, though enough stretching will deform them. The 0.5mm riveted links are still stronger than the 0.9mm butted links, at under half the weight. Most mail is flattened into discs. This actually makes it much stiffer, and resistant to stretch damage than round links. Also, the action of hammering the link work-hardens it a little more.
Oh, don't go for an axe yet. I'm firmly of the belief that no one should field with a sword till they've trained with a spear for a year..and you should field with a sword for a year before training with an axe. It's...hard to control it safely. As for shields...for 12th-14th, a heater shield is fine. There are descriptions of a Gallowglass in the early 1300s getting shot in the chest *through* his shield during a seige, so fine for Irish.
John






