Random BLAM! DIY Captain America Shield Out of a Satellite Dish
Published: December 8, 2010 - 6:26pm
Whether you're a long-lasting Cap fan or just can't wait for the first Captain America movie trailer, keep your Star Spangled spirits high with this do-it-yourself shield wielding project.
Instructables.com user Seamster recently submitted his schematics for a home-made Captain America shield that took a little ingenuity and a lot of elbow grease:
I'm not really into comics and the like, but I had been wanting to make a Captain America shield for some time. I originally tried using an old plastic sled, but it gave me all sorts of grief. The type of plastic would not take paint very well (not even Krylon Fusion for plastics), or any type of adhesive that I tried.
I eventually came across a used satellite dish, and with a little bit of modifying this turned out to the be best option for a Captain America shield. It will make a great gift for someone this year, although it will be hard to decide who gets it. I've got a handful of people that I know really want it. I may have to just sell it to the highest bidder! If you are interested in making one of these, you may have to do a bit of searching and asking to find a used satellite dish. I've seen them show up at thrift stores from time to time. Keep your eyes open, and you should be able to find one
Here are the first four steps to his project; to read the full 14 step process (or download the PDF printable file) visit Instructables.com:
STEP 1 - Disassemble the dish
I began this project by disassembling the dish and components with my Craftsman sockets and wrenches. Some of the nuts and bolts were kept and used later on to attach the handles.
STEP 2 - Draw circle
The satellite dish was an oval shape, and Captain America's shield is a round concave disk.
I was worried that a circle cut from the oval-shaped dish would look warped. But once it was cut out, the circle looked perfectly fine.
I eyeballed where the center of the dish was and put down three or four pieces of masking tape, which provided a place for the needle of my homemade compass to bite. I then drew as large a circle as would fit within the back lip of the dish.
STEP 3 - Cut out circle shape from dish
I initially tried using a metal cutting Dremel attachment to cut out the circle from the dish, but it was too tedious. I found that my metal snips worked much better for this task.
After the lip was cut all the way around, I used a dead blow hammer to pound the tabs all flat. I redrew the circle line with a sharpie so it would show up better, and then used my snips to cut out the circle.
I used a Dremel grinding bit to take off the sharp, jagged edges around the disk that were left from cutting it out with the snips.
STEP 4 - Fill bolt holes
There were four sunken areas in the dish for the bolts that needed to be filled somehow, and then ground off.
I used a Dremel grinding bit to remove the finish from the dish and roughen up the area around the bolt holes. I then used JB Weld to fill up the spots where the bolts had been. Masking tape was used to cover the backside of the holes while the JB Weld cured.