How to (not) Fumble Your Way Through Fabricating a Metal Captain America Shield, OR Learn From My Mistakes Because Metal is Hard by shinykari cosplay
First things first: This tutorial would not be possible without the immensely helpful and brilliant Valor from therpf.com. He did this first (and better!) and posted all about it, including photos and diagrams. I would highly suggest reading through that whole thread before reading this tutorial or even attempting to make your own shield.
This tutorial assumes you have at least some experience working with power tools. I had never worked with metal before, but am relatively competent with wood (sawing, drilling, sanding, etc.). That translated pretty well to metal, though there were some hiccups. I’ve added links to products where possible, to make sure I’m 100% clear about what I’m discussing. Harbor Freight is a really great store that carries a large selection of budget tools, which are perfectly fine for this project; I’ve linked to their website whenever possible, because cosplay is already expensive enough!
One more thing before I get down to it: always wear eye protection and gloves. ALWAYS. I cannot stress this enough. I know it seems like no big deal, what are the chances that I’ll get a splinter in my eye or whatever, but it really really is. Safety glasses/goggles and gloves are inexpensive and save you from sharp edges and flying debris. You also may want ear protection, especially when using the jigsaw and/or grinder. Those puppies are loud.
Since this ended up being a very, very long post, I’ve put all the materials and instructions behind a cut. You should definitely read through the whole post before you start (and Valor’s post too).