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

[Mordor Brass]

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




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.



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



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



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




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

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[Mordor Brass]

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.



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



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.



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





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.




Newt post. The wonderful world of cast and paint.


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[Mordor Brass]

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.



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.



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.



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.



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



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




Next post, the straps and the display.


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[Bogleo]

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]

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.



The aluminum buckle was from 3mm aluminum sheet.



Straps attached with Chicago screws



And the final assembly.

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.

 

[Mordor Brass]

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.



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.



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



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





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

Thanks for looking.


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[Mordor Brass]

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

How I promise, Better pics and a little update. A battle damage version.










I think it´s all.

Enjoy.

 

[breakfstmachine]

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

That is downright sensual. Fantastic work!

 

[Currahee12]

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

Te ha quedado de lujo, paisano.

 

[Mystery]

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

Amazing work!