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How to Create a Center-Held Round Shield




Today we are going to make a Round Shield. Yes... Yes... The kind that tables on you and flies around like it has a mind of its own, the Center-Held Round.

Something to keep in mind before beginning construction. Please wear all the appropriate safety gear before using any dangerous equipment.

First off, here is a list of Tools and Materials needed to construct the round shield.

Tools and Materials

(1) - 3/4" or 1/2" plywood board (your choice. I will be using 3/4")
(8) - 1/4" wide X 1 1/2" long Bolts Dome Topped Blots
(8) - 1/4" Washers
(8) - 1/4" Nuts
(1) - 3/4" thick X 9" Long, Aluminum Pipe
Metal Shears
Duct Tape
String
Pencil
1 Nail or Thumb-Tac
Power Drill
1/4" Metal drill bit
Jigsaw
Hammer
An Anvil or something like it.
A place to make a lot of noise and a big mess without too much complaint.



(1) How BIG would you like your round shield to be? 28 inches? 30 Inches? (Today I will be making a 30”wide round shield.)

(2) Make a loop at the tip of your string. Now make a second loop 15" inches up the string, or Half of the diameter of the shield you are making. (15" will be the exact middle of my 30" shield)

(3) Place your 3/4" Plywood flat on the ground and lightly drive your nail (or thumb-tac) somewhere in the middle of the plywood but make sure your string can never reach the side. Most likely somewhere in the middle.

(4) Now put one end of the string (the loop) over the nail and put your pencil in the other end. Pulling the string tightly outward run the pencil along the wood creating a large circle directly on the plywood.

(5) Now make a third loop in the string 3.5" from the loop you placed over the nail. and make a second smaller (7 inches wide) circle. This will be the location where the handle will be placed.
NOTE: You can make a larger circle if needed by increasing the length of the string.

(6) Using the jigsaw cut out both circles making an object that looks
a lot like a flat donut, and move the scraps out of our work area.

(7) Now place your Shield Boss directly over the hole and duct tape it down.Make sure it is as centered over the hole as possible.

(8) Now use your Power Drill with the 1/4" bit attached and drill 8 holes equally spaced around the parameter of the now taped down shield boss, about 1/2 an inch to 1 inch away from the outside edge of the shield boss.
NOTE: The more time you take making the holes evenly spaced the better your finished project will look. (I will only be drilling 4 holes for this demonstration)

(9) Run 2 bolts through the holes in the metal and thrugh the wood, then place washers and nuts on the back side and tighten them down to ensure you won't loose your marks. Make sure the head of the bolt is facing the front of the shield and the tail end of the bolts with the washers and nuts are on the backside.

(10) With your 3/4 aluminum pipe in hand, flatten 1 to 1.5 inches on either side of the pipe over and anvil.

(11) Place the flat ends over 2 of the holes you just drilled in the shield making sure that the 2 holes you choose are across from each other. Duct tape the handle down and drill through the existing holes and though the handle ends.

(12) Now push the bolts through the holes, with the handle in place, then tighten them down. Do this with all of the holes until every hole has a bolt, washer and nut in place.

(13) All that is left now are the simple touches of painting or staining and the protective edging around the shield. Decorate it and wrap it as you wish.

Enjoy your new shield and maybe make a few for close friends.

NOTE: If you router and sand your new round shield it makes it look a lot cleaner and can cut down on splinters and unsightly scratches.