Captain America Avengers Costume 2012 WIP - ceije

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Beatlesfan

New Member
I'm just starting on the same shield method with a Flexible Flyer sled (26"), and I was hoping you could answer a couple of questions. First, how did you take care of the lip around the edge? Second, what did you do about the handle holes? Thanks!
 

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ceije1010

New Member
For the lip on the sled I took a double bladed saw since those cut smoother with minimal kickback and cut it off. Then for any rough edges I took it to a bench grinder and evened it out. For the holes I did two things. My first few shields I used bondo with a small cutout of sheet metal as the backing. But it looks bad and doesn't always hold up. So I started cutting below the holes and removing them all together, which actually gave my shield a better dimension, took away some of the curvature at the edges that didn't look right.
 

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