This started me further down the path. I was in the middle of working on a production of The Lion, the Witch, and the Wardrobe and the director asked for a shield for the battle. So I started doing some research for methods to make curved shields. So I got online and found plans and instructions for a shield press which I built in the shop with some scrap material. I called for hardwood in a couple of places which I should have listened to. under pressure it popped and I wrecked the first sheets. Reinforced for the second time it all worked.
How the press works
After the Press
After they are free take the jig saw and cut out your shield shape. Its much easier to draw the shield on before you curve it.Cut it out and you've got your rough shape. Sand all the edges to smooth it up and I like to round everything over just because it looks a little bit nicer and makes things a bit less rough on the skin if it hits you at some point. After cutting them out you end up with something like this:
The white on here was just a primer, which is nice to add once sanded just for a basic shield blank. For added strength and paint-ability people cover the blank with canvas just for another layer. I skipped that here. First step was to measure everything out and figure out spacing. If you look at the center stripe I wasn't perfectly centered but you don't notice it much in person. I'll also note that I use carriage bolts for the handle and straps mostly for ease of repair. If something breaks I can just unbolt it rather than using a rivet which is much more permanent. So I striped things out and hit the red stripes. I won't show it, but let things dry, pull the tape up, do the blue, do the white etc.
Last but not least here's the almost final product. It needs another coat of white on the stars but its basically done. After it I'll add in some more pictures just so you can see other in progress moments and what the other shield ended up looking like.
If I haven't covered everything real well or if anybody wants more details on how I did something just let me know and I can go into more depth. Also let me know if there is interest in any of these I've got the press now and I'm thinking about doing custom shields for people if enough people want them.
Nearly the final product
Size difference between the two shields. The bottom is the Cap shield. These both came out of the 2'x4' sheet I pressed.
The back of the cap sheild. I use a solid metal handle for the grip. Some people use crossed leather straps I like the metal just because its rigid, I don't care if its not accurate. The pad in the middle is nice to soften blows and make it more comfortable to hold.
The final shield for LWW. It was a little quick so my hand was rough in a couple places but this is basically what the custom shields would be. Give me a picture, colors, design of whatever and I'd make and paint them. The next ones I think will just have a coat of arms type center image