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  1. RPF Premium Member Valor's Avatar
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    Milwaukee, Wisconsin
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    Oct 1, 2011, 10:59 AM - Metal Movie Cap Shield on a budget **DONE!! FINAL PICS ON PAGE 4 #1

    I've been drooling over the movie Captain America shields being produced here, but don't have te funds to buy one. So, I'm setting out to build one for $100-150.

    I started with a steel saucer sled found online. I trimmed the rolled edge and stripped the paint (sorry, I wasn't thinking of taking pictures for that part. Plus it was pretty messy)

    I then devised a way to produce the spun effect to the shield. I found the dead center at the top of the shield and drilled a small hole. I then attached a thin metal, flexible bar to the hole, like the hand of a clock. I then put a heavy duty stripping pad around it and spun the bar around in circles. I did the back of the shield the same way.

    For the star, I simple bought some sheet aluminum, drilled a tiny pin-hole in the center of the sheet and did the same spinning technique. I then cut the star out with a utility knife. I carved the lines in the star with a sharpened screwdriver. Some real rivets were added instead of the spun rivet of the real shield.

    For the back I cut the >< braces out of 1/8 aluminum and formed them to the contour of the shield. I mounted some threaded adapters I found at the hardware store to the back as mounting points for the four belt braces. The belt braces were also cut form 1/8 aluminum.

    For the strap rings at the outer edge of the shield I bend some steel into a clip which hooks over the notched edge of the >< braces. You'll see some paper strips in the photos that I am using to measure the amount of leather strapping I'll need.

    So, I still have paint and leather work to do. But I think I'll come pretty close to my financial goal. .... stay tuned.
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    Last edited by Valor; Jul 5, 2012 at 7:01 PM.
  2. Darkson's Avatar
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    Sep 2011
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    Oct 1, 2011, 12:47 PM - Re: Metal Movie Cap Shield on a budget #2

    Nice. Do the handle rivets show on the front of the shield?

    Looking forward to seeing how the paint job turns out.
  3. superDrool's Avatar
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    Oct 2010
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    Connecticut
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    Oct 1, 2011, 12:51 PM - Re: Metal Movie Cap Shield on a budget #3

    Darkson said: View Post
    Nice. Do the handle rivets show on the front of the shield?

    Looking forward to seeing how the paint job turns out.

    Was wondering that myself...

    Great job. I think you may have inspired a great future project for my son.
  4. RPF Premium Member Valor's Avatar
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    Oct 1, 2011, 12:52 PM - Re: Metal Movie Cap Shield on a budget #4

    Darkson said: View Post
    Nice. Do the handle rivets show on the front of the shield?

    Looking forward to seeing how the paint job turns out.

    Nope they are not visible, the allen screw go into a threaded fitting I found at the hardware store. It is mounted to the back of the >< brackets and secured with JB Weld.
    Last edited by Valor; Jul 5, 2012 at 6:56 PM.
  5. RPF Premium Member Valor's Avatar
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    Milwaukee, Wisconsin
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    Oct 1, 2011, 12:56 PM - Re: Metal Movie Cap Shield on a budget #5

    The only things I have had to give up on is the scored rings the original shield has. The metal saucer is far too thin to carve any effective grooves into it. Although, ounce the paintjob is done, I think I'll hardly miss them.
  6. Member Since
    May 2010
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    Oct 1, 2011, 2:49 PM - Re: Metal Movie Cap Shield on a budget #6

    That is pretty amazing, what are you using for paint? anoxidized spray paint?
  7. Member Since
    Apr 2011
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    104
    Oct 1, 2011, 2:52 PM - Re: Metal Movie Cap Shield on a budget #7

    Nice! Love the Wips pics!
  8. Member Since
    May 2010
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    157
    Oct 1, 2011, 3:03 PM - Re: Metal Movie Cap Shield on a budget #8

    Hey quick question, Ive heard chris evans mention that there were different shields for different scenes, he mentions a HEATER SHIELD....what is that?
  9. Member Since
    Nov 2009
    From
    Darkest Pordor - where the shadows lie...
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    265
    Oct 1, 2011, 3:32 PM - Re: Metal Movie Cap Shield on a budget #9

    Wow, man. Fairly ingenious. LOVE that star!

    If you offered the stuff you cut as kits so that people could hunt down the right sled and replicate your results...
  10. RPF Premium Member
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    Oct 1, 2011, 3:35 PM - Re: Metal Movie Cap Shield on a budget #10

    very nicely done! The center bolt with the sanding pad is how i did the finish on my prototype What's the diameter on this one btw? Great job on the handles parts as well.
  11. RPF Premium Member Valor's Avatar
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    Milwaukee, Wisconsin
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    Oct 1, 2011, 5:42 PM - Re: Metal Movie Cap Shield on a budget #11

    Some answers: First anyone could make this star. It was the part I was most intimidated by, but it was so simple. I traced a star onto the aluminum sheet. Scored it with a utility knife a few times and then wiggled the score till the metal snapped. No grinding, filing or anything.

    Second, I plan on using Duplicolors Anodized paints.

    Third, the diameter is just a smidge under 24"
  12. RPF Premium Member
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    Oct 1, 2011, 6:21 PM - Re: Metal Movie Cap Shield on a budget #12

    Yeah, how thin is that star? You know you should use that center hole on the main shield to make a fixture to mill in some grooves If not sure how, let me know. Keep up the great work.
  13. Member Since
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    Oct 1, 2011, 6:42 PM - Re: Metal Movie Cap Shield on a budget #13

    Deacon said: View Post
    Hey quick question, Ive heard chris evans mention that there were different shields for different scenes, he mentions a HEATER SHIELD....what is that?
    It's the original non-circular shield he used in the beginning.

    Awesome shield btw, it's coming out rather nicely.
  14. Member Since
    May 2010
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    Oct 1, 2011, 7:58 PM - Re: Metal Movie Cap Shield on a budget #14

    hashmodium said: View Post
    It's the original non-circular shield he used in the beginning.

    Awesome shield btw, it's coming out rather nicely.
    Thanks for the answer.
  15. SirRamenNoodle's Avatar
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    Jul 2011
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    Syracuse, UT
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    59
    Oct 2, 2011, 11:48 AM - Re: Metal Movie Cap Shield on a budget #15

    Great, great work! I'm learning a lot from your sled! Can't wait to see the paint!!!
  16. TheCap's Avatar
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    Aug 2011
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    Oct 2, 2011, 9:00 PM - Re: Metal Movie Cap Shield on a budget #16

    Very nice work, cant wait to see more! love the star and the strap brackets
  17. RPF Premium Member Valor's Avatar
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    Milwaukee, Wisconsin
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    Oct 4, 2011, 9:26 PM - Re: Metal Movie Cap Shield on a budget #17

    Painting has begun. First of all, the Duplicaolor Anodized paint (available at auto parts stores) are really fantastic products! I've just laid the red down tonight and the way the metal spinning texture shows through is great. The Photos look a little blotchy, but that's just the bad lighting in my workroom. The color's nice a smooth.

    Blue tomorrow!
  18. Darkson's Avatar
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    Sep 2011
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    Oct 4, 2011, 10:07 PM - Re: Metal Movie Cap Shield on a budget #18

    Nice. That blue is going to be brilliant on the shield.
  19. RPF Premium Member Logan Cade's Avatar
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    Jun 2008
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    Oct 4, 2011, 10:26 PM - Re: Metal Movie Cap Shield on a budget #19

    That is looking fantastic!

    I purchased those same paints; did you use the Adhesion Promoting Primer before hand, or did you just spray straight on the metal?

    Also curious to see what you think of the JB Weld and how it holds out, was planning my brackets on back the same way.
  20. RPF Premium Member Valor's Avatar
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    Milwaukee, Wisconsin
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    Oct 4, 2011, 10:29 PM - Re: Metal Movie Cap Shield on a budget #20

    Nope, no primer. I assume that would ruin the metal effect. You wouldn't see the metal grain through the paint. And, I think I'm going to go the route of industrial strength adhesive foam tape to hold the brackets to the back of the shield. I'm a bit worried about the shield flexing and popping the JB Weld off.
  21. RPF Premium Member Logan Cade's Avatar
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    Oct 4, 2011, 10:36 PM - Re: Metal Movie Cap Shield on a budget #21

    Industrial strength adhesive foam tape?

    That sounds really interesting.
  22. RPF Premium Member
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    Oct 4, 2011, 11:30 PM - Re: Metal Movie Cap Shield on a budget #22

    Valor said: View Post
    Nope, no primer. I assume that would ruin the metal effect. You wouldn't see the metal grain through the paint. And, I think I'm going to go the route of industrial strength adhesive foam tape to hold the brackets to the back of the shield. I'm a bit worried about the shield flexing and popping the JB Weld off.
    Haven't had any issues with the jb weld poping yet, and I even did a hand stand on the edge of my shield at dragoncon, lol. Much stronger than the foam tape. However, if your shield is steel, and the handle brackets are aluminum, Jb weld will pop right off if you leave in a hot car or something due the major thermal expansion difference in the two metals.
  23. RPF Premium Member
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    Oct 4, 2011, 11:31 PM - Re: Metal Movie Cap Shield on a budget #23

    Valor said: View Post
    Painting has begun. First of all, the Duplicaolor Anodized paint (available at auto parts stores) are really fantastic products! I've just laid the red down tonight and the way the metal spinning texture shows through is great. The Photos look a little blotchy, but that's just the bad lighting in my workroom. The color's nice a smooth.

    Blue tomorrow!
    That paint is beautiful isn't it! Great job. Becareful with the blue, test it first, some cans come out way too light blue colored.
  24. TheCap's Avatar
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    Aug 2011
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    Oct 4, 2011, 11:58 PM - Re: Metal Movie Cap Shield on a budget #24

    looking great man, cant wait to see the blue now

    as for the foam tape, not a bad idea at all, hope it works out well for you. i was thinking about giving the JB Weld SteelStik a shot since it does all metals, should check into it, maybe its something that would help you out.
  25. Member Since
    Apr 2011
    Messages
    104
    Oct 4, 2011, 11:59 PM - Re: Metal Movie Cap Shield on a budget #25

    That's looking Fantastic!! Good job!

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