If you’re having trouble finding a piece of cardboard big enough, check with some local businesses to see if they have any to give away. Places like post offices and grocery stores are often happy to get rid of surplus boxes. [3] X Research source A refrigerator box would make an ideal base for the rectangular, body-length Roman shield.
If you’d rather, if you can sketch the outline of your shield onto a separate piece of posterboard or scrap of newspaper first, then cut this out and use it to trace around the cardboard for a more precise shape. To account for the folded edges of your shield, draw two concentric outlines on the cardboard, one about 2" larger around the smaller outline. You’ll cut out the shield at the outer outline and fold it to the inner one.
Take extreme caution when handling any cutting tool. Straight cutters are designed to be very sharp, and accidents can happen if you’re not careful. Always cut in short, smooth motions and go slowly. You can use scissors if you have no other option, but the blades are not as sharp, and the pressure of them against the cardboard may cause it to crush and cut poorly.
Remember to cut the outline of your shield several inches larger if you decide to fold the edges of the cardboard.
If you wish, you can cut a second strip of cardboard to serve as a forearm strap, which will brace the shield against the forearm and allow you to control it better.
Assuming you don’t want to spend the money to have a piece of wood cut specifically for your shield, you can visit a lumber yard or recycling center to salvage unused scrap wood for little or no cost. If you’re unable to find a wood board large enough, piece together one of the right size using smaller individual pieces, like planks from a wooden pallet.
A plain metal handle will look best in keeping with the appearance of the shield. Scrap leather can usually be bought in craft stores, or online. Cut the leather to the exact size you want for the strap. [11] X Research source You will only need two wood screws, unless you decide to attach a leather forearm strap as well, in which case four will do the job.
Cracks or breaks in your wood board can be sealed using Epoxy. [12] X Research source
Allow room for a strap. If you wish to add a leather forearm strap in addition to the handle, account for this in the layout on the back of the shield. Measure the distance from the thickest part of the forearm to the palm. If you’re right-handed (which means you would carry the shield in your left hand), place the strap and handle the appropriate distance from one another in the center of the shield with the handle on the right. If you’re left-handed, reverse this configuration. To center the handle and strap together, take a measurement of the total width of the shield and subtract your forearm-to-hand measurement from that, then divide this number in half to tell how you how much space you should have remaining on either side of the strap and handle once they’re attached.
If you’re bolting the handle to the wood, use the paddle bit to bore about half an inch into the wood, then drill the rest of the way through and insert the bolt. Tighten with the socket head bit. [13] X Research source Plywood and other lightweight pieces will likely be too thin to bolt successfully.
Print a template off the internet and make it a guide for a stencil you can use to spray paint your design on for a clean finish. [16] X Research source Create your own original design in the same style as traditional Roman weapon-works for a personalized shield. Use painter’s tape to help you paint precise lines and edges.
When applying lacquer or any chemical gloss, be sure to do so in an open, well-ventilated area, and wear a face mask if possible.
To increase the safety of your shield for recreational use, add a few strips of foam around the inner edge of the shield (the side you’ll be on while holding it) to pad it against your own body.
If you plan to use your shield when it’s not being displayed, find a place to attach the framing wire where it won’t interfere with your grip.
