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Daily Mail Online has an article about their writer's experience being on the set of Merlin as one of Camelot's knights, with behind-the-scenes details and quotes from some of the cast. Here's an excerpt:
The only trouble is, it’s all so heavy that the moment I try to move, the sweat begins to pour off me and I’m in danger of rusting the chain mail. Fellow knight Sir Percival (played by Tom Hopper), says he knows how I’m feeling. ‘On the plus side, it’s actually quite a decent work-out, especially when we’re having to scale a lot of rocks, which we do in this series,’ he says. ‘It saves having to go to the gym.’
You can read the full article, which contains spoilers,
at this link.