Yeah I've got the same issue. What are you making your scale mail out of? I'm using plastic spoons. I don't want to use plastic spoons, someone had suggested craft foam, but the niece insists on the plastic spoon thing. I'm begining to not like that kid so much this week.
Anywho, I had planned to use the heat gun to bend each spoon down, and shape it to fit, but the kid likes the way the spoons stick out. Kids,
. So the new plan is to glue the spoons in place and insert something inside each gap. I don't know what I'm going to stuff in there, a feather, a bead, a gem, a squirt of that puffy fabric paint? It's a make it up as you go dark fairy costume, so I have the luxury of being able to just sort of make it up as I go along.