1 sheet 1/2" good interior grade plywood available at Home
Depot. Avoid warped or
excessively knotted plywood.
(It's really 5/8", they just call it half inch.) If you
can get it and you know what you're doing, the plastic curved
scutum is the way to go. (Not recommended for beginners, though!) To
size the core, take 3" off
left, right, and top and bottom of the FINAL shield size you want
(for a rectangle tower shield).
2' by 4' sheets from Home depot will allow for up to a 2.5'
(30") wide by 4.5' (54") shield. Your finished shield
should cover you from your throat to your knees.
Use a file or a sander
to smooth the edges of
the wood core--just a little, to *just barely* round the edges and
remove the sharpness and any burrs from the cutting.
and hand Grip. (Yes, historic Romans used punch shields. I
don't recommend it for Dagorhir combat.)
Use thick leather (or some *proven*
man-made substance) of at least 2" wide and 3/16" thick
for the forearm strap.
Use a Home Depot cabinet handle for the hand grip.
Get nuts, bolts, and washers and lock washers for the strap and
2 sheets of the 2" thick 24" x 48" Unifoam
for $23.95 (This will be enough for even a very large shield.
You'll have extra for javelins. If you can find 1.75" or
1.5" thickness, that will work too. Occasionally Rome buys a
large stock for a significantly lower cost. But we have none at
1 sheet of 3/8" thick EVAlite
1/2 sheet of 1/2" EVAlite (McMaster-Carr
You can substitute EVAlite for a regular 3/8" camping pad
with decent results and a significant savings. But I recommend the
EVAlite for longevity. And for swords.
1 can of 3-M "77" (multi-purpose) spray adhesive (or
perhaps 2 cans for 3 shields; about $10 each at Home Depot)
LOTS of fresh "standard" exacto knife blades for cutting
1 2" long foam-cutting knife blade per shield to
cut the Unifoam
thick foam neatly *requires* a really long and sharp blade and is
the trickiest part of making one of my shields. Fortunately,
rectangle shields are all straight cuts.
1/2 roll of 3M duct tape
1 Metal yard stick
for measuring and cutting.