This build is for my subscribers that not only wanted to have a cheaper build process, but easier parts to buy if you live across the pond in the States. This time I have used a steel saucer as a mold, and again it can be used over and over again to make as many shields as you like.
Steel saucer mold
The main change this time is the use of a ‘Flexible flyer’ steel sled saucer as a mold. While you can’t go full size (2½ feet) with this saucer it’s still a very nice 2 foot wide, ideal unless you are 6’5″ and 18 stones. This of course keeps the other materials like fiberglass resin and fiberglass mat usage down as well.
Fiberglass resin
As with the mark 1 build, this also uses cheap polyester fiberglass resin, the same as used in car and boat repairs. Nothing fancy is required. For a standard 24″ shield expect to use 600-800ml (20-27fl oz) of resin per layer. I used 4 layers, but you could easily use 3, or even 2 if you are on a budget or need super light weight.
This means that for a 2 layer shield you would require approx 50 fl oz, 3 layers is 75 fl oz and 4 layers 100 fl oz. You can buy up to 1 Gallon (128 fl oz) of Bondo on eBay or Amazon.
Fiberglass mat CSM
I used 450g (1.5oz) Chopped Strand Mat in the video, so for a 4 layer shield you will require 2 yards of CSM fiberglass mat. 2 Layers would obviously only require 1 yard of the 50″ CSM. Again check Amazon, eBay and Google for supplies.
Cutting build costs further
Here’s a suggestion for reducing the final build costs again. When you have finished with your old Flexi flyer mold why not list it on eBay as a mold for a captain America shield, complete with a link to my video on how to build the mark 2, and the destruction testing video. The links for which can be found in the ‘share’ bar underneath my videos on YouTube.
Final decoration
A video on how to paint your new shield can be found here. The star design is taken care of by adding a thin 0.5mm aluminium sheet (approximately somewhere between 1/32nd and 1/64th”). There are two downloads to choose from here, one is a Docx where you can scale the image yourself, and the other is a standard jpg file. Scale the star up so it fits the size of your shield, if you need the star larger than your printer will allow simply blow it up so that some of the star is missing and print two, then tape them together.
If your flyer sled is the same size as mine, which it might be, I put marks in at 63mm, 63mm, 63mm and 111mm for the circles to the face of the shield. The star then sits in the inner circle.
The above project is for consenting adults only and is for education and entertainment only.
This project contains danger when working with not only power tools but also sharp edges on the fiberglass when cured. Fiberglass strands can puncture skin, and fiberglass powder from cutting and sanding is an irritant and breathing hazard, so protective gloves, clothing and the appropriate face mask should be worn. Full wrap around eye protection is vital when mixing and working fiberglass resins or other chemicals. The appropriate face mask should also be worn when spraying any aerosols. Always read any safety advice or technical sheets provided with any products or materials.