Gondorian War Shield Build

QEProps

New Member
Hello all! I've been posting images to the group facebook page for a while and I figure it's about time I put up a thread here on one of my props. I started a few weeks ago working on a replica of the Shield of Gondor from the Lord of the Rings.
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I started with two plies of 1/8" MDF sheet that were glued together over a shield press. The two plies are the core of the shield, a third piece was wet formed over the press by itself. The front of the single layer and the back of the core were painted using a wood graining tool to simulate real wood grain on the outside. I then cut it into strips to create the slats for the front of the shield. Before glueing the slats down I drilled holes through the core pieces for a set of 6 elevator bolts that would be used to attach the leather straps later. Elevator bolts are like carrige bolts but with extremely flat heads. I recessed the bolts so they don't interfere with the slats and then epoxied them in place before glueing down the slats on the front.
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I used a fourth sheet of 1/8" MDF to cut the upper and lower bands for the front and back of the shield. These were cut while flat and they were clamped in place while the glue dried.
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Started working on the tree after that. I printed an image to the size I wanted and then cut it out with a hobby knife. The patter was placed on a fifth sheet of 1/8" MDF and I lightly sprayed paint over the pattern to make a stencil to cut out. Unfortunately the size of the tree made it so that nearly all of the interior cuts meant that I couldn't cut it out on my scroll saw. Most of those spaces had to be cut out by hand with a hobby knife and a detailing saw.
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It took several days of hand cutting and sanding to create the tree. I'm going to need a laser cutter if I'm going to attempt this one again.
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After the tree was done and in place I used Apoxie sculpt to create the crown and stars around the tree.
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The rivets were created with fast curing resin poured into molds I had created in some clay. That way each rivet is unique. A little bit of paint, and some leather straps on the back and the shield was done! I have a friend that does costuming and works at Badali Jewelry. I loaned the shield to him for display at their booth at the convention, it was a big hit!
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The handles are ambidextrous. Two leather straps are bolted down on the sides with two loops. The lower loops are larger so that when you place your forearm through the lower loop and grab the upper loop on the opposite side the straps are snug. Overall the shield weighs about 12 pounds and is fairly comfortable to carry. Final dimensions are 23" wide and 46" tall, 5/8" at the thickest points.

I stopped by the booth to pick up the shield and add a few autographs from the guests of the convention. Sean Astin, Billy Boyd, and John Rhys-Davies were all kind enough to sign the back. There's still plenty of room for more when I get to meet more of the actors! Billy Boyd was really excited about the shield, he said "It looks amazing! And I spent a lot of time in Minas Tirith, so I should know!"
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I've run a wire across the back between the two handles that I can use to hang the shield from a hook on the wall. It looks great next to my Vera signed by Adam Baldwin! :D Please feel free to comment or ask questions!
 
Fantastic, a wonderful piece of work there! Sig's are a great addition, well done mate!


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Absolutely outstanding work, I really want to make a full Gondorian suit soon, I love them too much. This was inspirational to say the least :)
 
Not sure why this post doesn't have more views/comments. Like said earlier, This is fantastic! Your work on the tree design is amazing! More please!
 
Not sure why this post doesn't have more views/comments. Like said earlier, This is fantastic! Your work on the tree design is amazing! More please!

I don't do a good enough job sharing my work here on the forums. I have a few other threads around about my Vera from Firefly, a Destiny helmet, and a new one for my Sgt. Calhoun rifle. I need to be more engaging in my posts I guess! (and check more regularly) ;) Thanks for the comment!
 
Looks great. I was wondering if you could post some dimensions, ive sent a couple PMS to other people who had made a shield but cant get any responses.
 
Looks great. I was wondering if you could post some dimensions, ive sent a couple PMS to other people who had made a shield but cant get any responses.

It's 23" wide and 46" tall. 5/8" thick at the thickest point, not counting the rivets across the top and bottom bands.
 
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