Captain America movie shield. The most difficult DIY shield I´ve never made before.

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Mordor Brass

Active Member
Hi guys. Recently I´ve been working in my own Cap´s shield movie version. This time I would like to make a very decent replica for me and why not, I would like to sell some pieces becouse in my country the Cap´s shield are hard to find. Here the full process from to make the model to molds, casts and paint.
Sorry the quality pics from my phone.

I started with an old fiberglass cast ( and last piece) from my old mold of Cap´s shield comic version from a satellite dish.

http://www.therpf.com/showthread.php?t=120774

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The circles was milled with a Dremel. Front side and backside. Also I gained the edge with bondo. I used foam tape to make a clean edge. Once bondo was cured, I peel the tape and Tadá, clean edge.

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The star was engraving with a metal marker and hand made chisel.

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To make the brackets I used foamed pvc and to simulate de ribets, I made a special drill with aluminum rod with teeths.

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With primer all looks better. 2K automotive primer used.

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Next part, the mould. The big mould. Hehehe.

You can find us and our works at Facebook:https://www.facebook.com/pages/Mordor-Props-Workshop/259930630823592?ref=tn_tnmn
 
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Mordor Brass

Active Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

Ok. We continues. The shield´s mold was my first big mould. I used the two parts molde with fiberglass jacket and silicon core.
First, I covered the shield with plastic food to protect it from dirt. Once I covered with water base clay and I sculpted the keys. Once sculpted, I sprayed acrylic clear coat to help the demold from fiberglass jacket. Once clearcoat was dry, I brushed mold release wax. Petrolleum jelly can work too. I covered the clay with polyster resin with fiberglass. The pipe in the center is for pouring silicon late.

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Once the polyster cured, I removed the jacket and remove the clay.

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It´s time to pouring silicon. I drilled some holes in the keys of the jacket mold to let scape the air when you pour the silicone. I relocated the jacket over the shield and I screwed it to the table. I put some hotglue around the jacket to prevent the silicon scape. Once the silicon was poured, I cover the miniholes with screws.

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Once the silicon was cured, repeat the same process with the backside.

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To attach the two fiberglass jackets I made holes when the parts was together ans used hex screws. Sorry, I forget take pics.

Here the master and the mold ready for cast some pieces. The bit purple in the center of the front side was becouse I used other B silicon part in the last pour becouse I consumed early the original B compound. Luckly it worked.

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Newt post. The wonderful world of cast and paint. :)


You can find us and our works at Facebook:https://www.facebook.com/pages/Mordo...92?ref=tn_tnmn
 
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Mordor Brass

Active Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

Really when I arrived to this part, I didn´t know what kind material cast I would use. My first try was my first time with epoxy resin. I used epoxamite from Smooth-On. It´s a awesome resin. I´m in love. The final piece is lightweight and very very strong.

I laminate the front and back side separately. First coat with thixotropic aditive (Aerosil) and black pigment. Second coat resin+fiberglass.

Once semicured the two sides, I put a resin cord with thixo around the edge with a pastry bag. And yes, a pastry bag is perfect if you put thixoresin inside and you want total control where you put resin. Sorry I haven´t pics of this process.

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Here the final cast. Some little bubbles but it´s not a problem. Mr putty tu the rescue. No pics of the front side. Sorry again.

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Now the funniest part.(sarcasm) Painting. Transparents colour is soo dificult to apply.
I used 2K automotive primer and once cured, I sanded the surface of the frontside in one direction with 60 grit sand paper to get the brushed metal effect.
Silver colour base coat aplied with spray gun.

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Masking tape the star and the circles and first coat of Metalcast Blue from Duplicolor spray. I need say I didn´t use the spray can. I emptied the gas inverting the can and once without gas, I made a hole in the can and I extracted the paint for use it with a spraygun. It´s not very recomended but it works better than can´s diffusor.

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Some process with the red colour. Metalcast Red from Duplicolor.

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Once applied the colours, and some light weathering, I clear coated with satin 2K automotive barnish.

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Next post, the straps and the display.


You can find us and our works at Facebook:https://www.facebook.com/pages/Mordor-Props-Workshop/259930630823592?ref=tn_tnmn
 

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Bogleo

Well-Known Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

Your pictures in the last post aren't working. Also, what is the diameter of the shield?
 

Mordor Brass

Active Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

As my sewing machine can´t sew leather, I used upholstery faux leather with eva foam core.

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The aluminum buckle was from 3mm aluminum sheet.

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Straps attached with Chicago screws

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And the final assembly.

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Your pictures in the last post aren't working. Also, what is the diameter of the shield?
Ops, sorry. The posts don´t let me upload 24 pics. I´m trying fix it. It´s my first time posting a lot of pics.

The diameter is 68 cm.
 
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Mordor Brass

Active Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

For the display I thought in a wall display andI designed a piece where the shield could rest. I made the master piece withfoamed pvc, mold it and cast in polyurethane resin with aluminum powder.Coldcast. I mounted the pieces in Y structure.

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Left, silver paint. Center, polyurethane withblack tint + aluminum powder. Right, Polyurethane Smooth On 326 + aluminumpowder Finally I´ll use normal resin and I´ll finish it with silver paint with weathering effect.

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The Y structure. I know. It´s very simply. But it works hehehe.
The upper piece can unscrew to dissassmbly the shield from display.

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And the final mounting. This is the 00 piece. The first prototipe I´ve finished. Soon I could calculate costs for a little wave.

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I hope you enjoy with the process. Next week an profesional photographer will take better pics. I promise I´ll share.

Thanks for looking.


You can find us and our works at Facebook:https://www.facebook.com/pages/Mordor-Props-Workshop/259930630823592

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breakfstmachine

New Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

That is downright sensual. Fantastic work!
 

Currahee12

New Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

Te ha quedado de lujo, paisano.
 

Mystery

Well-Known Member
Re: Captain America movie shield. The most difficult DIY shield I´ve never made befor

Amazing work!
 

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