For Halloween this year the family is going as some of the Avengers, so I chose Captain America. The sled I used to make this shield was already used once as the shield for my Spartan Hoplite Costume so I needed to repaint it and make new handles. The construction part of this was pretty simple and straightforward, but the painting was a bit of a nightmare; I hope you will learn from my mistakes! I used only materials I already had at home other than the paint, so feel free to get creative with what you have available!
This isn't a movie-perfect recreation but it is a pretty easy process and makes a great halloween costume! You'll notice particularly the shield isn't actually even a perfect circle due to the hand holds in the sled, and the straps are functional (so you can hold the shield with one arm or behind your back) but do not resemble the movie straps. Also it's plastic instead of vibranium so not useful in combat.
-Round plastic 'saucer' style kids sled (28 inches across)
-8 D Ring style picture hanging hooks with screws and bolts (small!) to tie the straps
-Fake leather costume material (for hand straps) and leather string (for shoulder straps)
-Metallic spray paint - silver, red, blue
-Plastic Primer **I Didn't Use This But I Should Have!! Please Learn From My Mistakes!**
-Spray sealant (I used Krylon Triple Thick Clear Glaze but that's just what I happened to have at home)
-cloth measuring tape (for measuring the curved surface of the shield and to use as a compass to draw circles)
The first step was to drill the holes for the handles and a small hole in the very center of the shield for measuring and drawing circles. Use a bit that corresponds to the screws you will use for the D ring hooks.
There are 2 holes for each of the hand straps and 2 holes for each of the shoulder straps, so a total of 8 holes to drill for these, plus the 9th hole right in the center to help draw circles.
I drilled my hand holes about 5.5 inches apart per strap, and the straps are about 10 inches from each other, roughly centered on the shield (note that the holes from the previous life of the shield (the larger ones in the photo) were offset from center, but for this build I made the straps centered).
The shoulder strap holes are about 15 inches apart per strap, and the straps are about 14 inches apart.