Titu Cusi saught to replace old bronze weapons with more European style replacements
Titu Cusi’s power waxed and waned, depending on where in the empire one was. Obviously those in lands no longer ruled by the Tawantinsuyu were not under his sway, but even amongst those lands still under the authority of Cusco, he did not wield total power. As Inkap rantin he did hold power in all of the empire, but this power was mostly in the form of administering the decrees of the Sapa Inka, not crafting his own reforms. In what remained of Chinchaysuyu, Antisuyu, and Kuntisuyu he would face local powers. The three suyu did not have the de facto independence Quallasuyu did from imperial power, and years of rule by Cusco meant that they were not inclined towards resisting top-down pressure. But these suyus still had their own Apus, and other officials with direct lines of communication to the emperor. And, although Titu Cusi was a master of kissing up to Quisipe-Tupac, they could often be quite convincing when pleading to the Sapa Inka. In addition, while Titu Cusi sought to restablish imperial power everywhere he also wanted to ensure said power remained in his hands, and so was reluctant to do anything that would threaten Quillota’s status as the heart of the imperial revival. So Titu Cusi’s efforts must be assessed in pairs, what happened in the Quallasuyu and what happened outside of it.
Military modernization had been a key goal of the Tawantinsuyu ever since they had first captured the Spaniards. By the 1550s Spanish advantages in warfare had not been neutralized, but that had been normalized. Any man who was in any way trained for battle would not run at the sound of gunfire, and did not think Horses anything more than mere beasts. The issue was now quality and quantity, not mere knowledge of the European weapons. Horses had proliferated through the Tawantinsuyu and even beyond the empire’s borders. The Spanish still more and better horses, but the Tawantinsuyu had enough that no longer were they a precious resource to be jealously guarded at only one site. All horses in the empire were naturally the sole property of the Sapa Inka, but many were used for transport or as beast of burden instead of solely cavalry. Said cavalry was a focus of Titu Cusi’s reforms in the military. Intense training was required to ride, and still the Tawantinsuyu cavalry was inferior to the Spanish. Rectifying this would prove difficult. There was very little natural terrain for training, and there were no lands where men had been with horses since birth. Titu Cusi did his level best in training and did make some progress. He found that those Mapuche who had remained in their homeland following the conquest remained had adapted horses to suit their homeland, and so reluctantly recruited them into his forces, although he never would fully trust them and with good reason. In time Titu Cusi advanced the cavalry of the Tawantinsuyu to new heights, but they were not yet on par with any of their European counterparts. The breeding stock was lesser, they did not have years of tactical experience with fighting on horseback, and the wave after wave a plague decimated the cavalry just as it did everything else in the empire. The effects of his efforts were generally equitable over the entire empire, seeing as how there were horses everywhere. However, the best cavalry would indeed be found in Quallasuyu.
When Europeans had first arrived in the region, the Tawantinsuyu had been in an age a bronze, and since that time iron and steel had been some of the most valuable items in the empire. Indeed, the invasion of the Mapuche had been nominally aimed at securing iron deposits for the Tawantinsuyu. Such efforts proved unnecessary, as the iron deposits cultivated by the Apus of Quillota had almost entirely already been in the Empire. Several important mines were established in various locations. One was established along the coast, near beaches where a colony of dolphins often swam, and so earned the nickname “phujpuri”. Another was established further North, and was called “thalthal” after local claims of birds in the night. Finally one was established somewhat near the Maule river. A local legend soon emerged, that the mine was at the site of the famed Battle of the Maule River, which had defined the Southern border of the empire for years. This legend was almost certainly false, but it did earn the mine the nickname of “maqanakuy” for the battle that had supposedly taken place there. Finally one mine was established in Kuntisuyu, again on the coast, and not given a name save for the name of the suyu it sat in[1]. The mines were mostly manned by mita laborers, paying their debt to the Sapa Inka by way of their work, and marked the first real application of the mita system to mining in the history of the Tawantinsuyu. In theory this was only supposed to be seasonal, but in practice they were worked year round, removing worthless copper[2] and mining out the valuable iron ore. The mines were under the strict control of Titu Cusi in his position of Apu. Even ore mined in Kuntisuyu was sent South for smelting.
The Bloomery was the backbone of Tawantinsuyu iron and steel production
By decree of the Apu, all iron and steel production was to be done in Quillota. The river nearby, the Aconcagua, would be the source of power for the bloomeries that emerged, the water wheels turning and turning ore into iron. Men and women toiled, creating iron from the ore. Again and again iron was thrown into the furnaces. If steel was needed, and it often was, yet more work was required. Captured Spanish, then voluntary Spanish, then voluntary Portuguese had granted a base of knowledge, and the Tawantinsuyu had, through trial and error, begun to produce iron and steel of reasonable quality. It was not as good as in Toledo, and it was indeed quite limited in scope and quality by European standards particularly in terms of steel. The Tawantinsuyu lacked knowledge of blast furnaces, which made production far more efficient in Europe. Nonetheless, when a soldier in the imperial army drew a blade, it would not be copper and tin, but iron and sometimes carbon. But the average man would not get a true blade. Captured blades had long been a status symbol among the nobility, and Titu Cusi, ever the people pleaser, was hesitant to displace those who had been favored previously. And, desperate to maintain a monopoly, Titu Cusi remained extremely selective about the distribution of forged weapons, to the point of harming the effectiveness of his army. There was also the matter of smithing. The Tawantinsuyu could smelt and smelt and smelt, but they had no true experts in working iron and steel into swords or other weapons. The well trained gold and copper workers could fashion weapons well enough, but the quality again remained low. If a piece became unworkable it would be refashioned into a club or mace.
Quillota was also home to the powder mills of the Empire. Very few Europeans knew the formulas commonly used for gunpowder, and fewer still the process for refining the saltpeter needed. Acquiring charcoal was easy enough, Titu Cusi ordering swaths or threes felled and burned in the jungles of the east. Sulfur too could be found easily. The slopes of Tacora, an ancient volcano in north-central Quallasuyu, had plenty and was sent south to Quillota.
No the problem was saltpeter.
Even among Europeans the methods of producing saltpeter were kept secretive. Gunpowder was a lifeblood of war, and those who controlled the supply could at the very least turn a profit, if not strangle their opponent's ability to wage war. In the days of Titu Cusi’s father some saltpeter had fallen into the hands of the Tawantinsuyu from captured Spaniards, but little of that remained. Half heard tales from Europeans and trial and error had led to a small nitrary being established. Human and animal waste was packed in with plant matter and left. If they were lucky, it would then produce a product that could be scraped up and boiled to make the saltpeter. It was slow process, and with no experience in the process whole batches were often lost to mistakes. So the Tawantinsuyu had a very limited supply of gunpowder to start with[3].
And it wasn’t always very good gunpowder either, often containing lower amounts of saltpeter then was needed. In his everlasting bid to garner support Titu Cusi would often show off the power with displays of explosions and fire, but failed to mention that the powder used was useless in the barrel of a gun. What little useful powder existed was kept in the hands of the Apu, for use by his gunmen or artillery. The weapons themselves were either captured from the Spanish or bought from the Portuguese for extremely high prices, Titu Cusi deciding that with what little powder he had manufacturing guns locally would not be worth it. Even with the low number they possessed the guns of the Tawantinsuyu were still filled mostly with European powder, at this point in history purchased either from enterprising Spaniards or enterprising Portuguese.
The great mass of men armed with modernized weapons was based in Quillota, as was to be expected. While Titu Cusi lived in Cusco, his base of power remained in the South. The men entrusted with the city in his absence were a cadre of nobles who had actually originated in what was now the Kingdom of Kito and who had followed the army South and ended up being stranded there. A few guards were naturally posted in Cusco, it would not do for the Sapa Inka not to have power over at least some guns, and various important figures were given the “honor” of owning a gun. But the real power remained in Titu Cusi’s control and stashed in Quillota. At least for now.
In early 1557 crews of laborers broke ground some five mile northwest of Cusco on a new mountain fortress. With the loss of Tumbez all those years ago the most modern fortifications of the Tawantinsuyu had been lost, and the Cessation of Faith had given the Spanish land well into the mountainous interior. No longer could invaders simply be stopped in the foothills, and with the border now closer to Cusco then in living memory, it was time that the capital got a strong defense once more. This first fort was situated along the road leading towards Spanish territory, and would theoretically serve as a bastion that protected the capital from all threats. Titu Cusi hoped to follow it up with another fortress on the roads headed towards the coast. However, the fortress would never be as grand as he had hoped.
Firstly Titu Cusi, in his rush to emulate the newest of modern tactics, ordered that a star or bastion fortress be built. Such fortresses were useful in the flatter and more costal regions of Europe and, while not useless in the mountains, were not as necessary when an attack was likely only coming from one side. Secondly, star forts were manned with a complex set of batteries that engaged in covering fire of blind spots with precision being needed to defend effectively, a tactical expertise that no gunners in the Tawantinsuyu had yet developed. And Titu Cusi did not have enough heavy guns or powder to man the fortress either, especially when the Spanish raised a ruckus about what they saw as an aggressive move, and which Quisipe-Tupac, not wanting to be surrounded by his cousin’s forces, agreed with. So Titu Cusi agreed to “voluntarily” limit the number of men and guns in his new fortress. This left the builders building a fort that was much larger than it needed to be. It would be several years before it was completed, and by the time the expensive project was over, Titu Cusi was forced to abandon any hope of more fortifications.
During the years of peace that followed 1556, Titu Cusi’s military achievements were generally successful when they were continued from previous Tawantinsuyu efforts, but failed to present any great leap forward against the Spanish.
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1: The Mines listed above are near or at the towns of La Higuera, Taltal, and Romeral in Chile and the Marcona district in Peru respectively.
2: This is not really accurate, bronze (and thus copper), is still the backbone of Tawantinsuyu metallurgy and are still widely used.
3: The irony here is that, being into control of OTL Northern Chile and the coast, Titu Cusi is in possession of some of the best gunpowder making material the world has to offer. Wars were fought over it IOTL. But at this point in history Nitratine has not been identified as a viable source, and while guano is known to certain people near certain caves it is not a widely sought after source. So for now, the Tawantinsuyu struggle to produce saltpeter, while atop a mountain of it.