Here's the final foam for the goggles. I decided that the rubber and elastic band in in the film are most likely grey, not white, so I dyed the elastic and bought some grey foam:
I also purchased some leather, because the real goggles of the era had leather backing on the rubber, and because the foam alone was too flimsy, and I thought I might need to sew the lenses on:
And here you see the final goggles. The bit between the lenses is wood covered in aluminum tape, and held in place with more tape between the lenses. I tried to find a way to make it hinged, because it needed to be flexible to wrap the goggles around the helmet, but the tape is the only solution I could come up with on short notice.
(The "strap" below the goggles is a surplus sweat band which I picked up for $4.)
Closeup of Cap's goggles for comparison. My goggles were $10 + $6 for elastic, foam, and leather. Replicas of the exact WWII goggles he wears here go for $250. Real WWII goggles go for around $300-$500:
And here's the finished shield!
I used reference photos from the film when distressing it. The weathering was done with black and white paint markers, black paint soaked into a paper towel and dabbed on or rubbed in, aluminum paint brushed on with a 1" brush slightly wet with paint, and fuller's earth mixed with some water to make mud which was also brushed on. Sandpaper was used in spots to cut down the work with the paint markers to make the marks look more real.
I missed the silver in the bullet hole, but I might add that later.
For comparison:
I gotta tell you I was worried when I started weathering the shield that it was gonna look like garbage and that I'd screw up a beautiful prop, but I'm really happy with the end result!