FOAM BUILD Captain "Canada" Shield

[zacic]

I really wanted to have my own Captain America Shield to hang on the wall and generally be a annoyance with so I could throw it around and have fun, so I tried my hand at making my own, using EVA foam, which is the easiest thing to get a hold of where I live.

Using some of the sideshow and different replica sites I got the dimensions for the shield, about 27 inches in diameter and about 6 inches in I guess what you would call depth from the center to the edge of the shield which would give it the correct curvature.


So first I had to create something to cut a perfect circle out of the foam since my largest circle cutter only does 10 inch diameters,

Using a wooden ruler, some clamps, a screw, and an exact-o blade, I made a nice easy to change large circle cutter, it can do up to 30 inch circles with no problem.

I used a Japanese pull saw to cut the slots in the ruler, the blade was just small enough to allow the knife blades to slide in snugly and the clamps were just to keep it from moving around and add weight.

once I had it cut out of the 1/2 inch Eva foam, I used a right angle to figure out where I would have to cut the sections out to curve it as well as figure out how much i would have to cut away.

once that was done I cut out a similar sized piece of foam, this time only 1/8 thick, to use as a backer to keep it in the correct shape

I didnt take any pictures of the next few steps but I cut out sections to create the shield look that I wanted to get

as well as my own spin on the center emblem since I live in Canada

here is a size comparison next to the EVA Hammer Ive also been working on

once that was finished I added some extra support parts to it and using some leather strips I made the arm supports for it, I may alter it so I can get it to sit on my back like in the movies but for now it sits quite nicely on my forearm.

once I play with it a bit more I will paint it White and Red to match the Flag.

hope you guys enjoy looking.

 

[GoldPhive]

this is pretty cool! im wondering how sturdy it will be considering its made of eva foam. even for recreational use and maybe a GIANT fame of ultimate frisbee, i think you should find some sort of semi-solid core. i myself would like to build a spun aluminum Captain "Canada" shield but am not sure where in canada to get that done. good luck on the build!

 

[zacic]

thank you, I took it out to the park with some buddies and we tossed it around like a giant frisbee for an hour and it held up great, that was after I gave it a good spray of Plasti Dip which seems to soak into the foam and make it pretty rigid but still flexible.

 

[Fly4v]

Clever way to make a flying shield.

I like the stealth black but for your red shield can you buy red foam for a no paint build?

 

[zacic]

unfortunately I have not been lucky enough to find any place that sell 1mm eva foam large enough, If anyone has a supplier that does I would love to know. as for right now Im going to give it a few more coats of plastic and then start adding the colors to it using the same kind of plastic coating.

 

[zacic]

It finally stopped raining long enough to get outside and paint, I masked off all the areas I wanted to keep white and gave it the good old Canadian white and red, a few bits still need to be trimmed but ill do that after the paint dries.

 

[Fly4v]

Can only say one thing, "OH Canada!"