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This is a flying Captain America shield that you can make out of duct tape and cardboard. Make a couple of these and you can battle it out with your friends Captain America-style!

I had two goals in mind with this project: 1) that the finished shield could be tossed around safely and actually fly stable like a giant Frisbee, and 2) that it could be replicated by almost anyone, independent of their current crafting skills.

For this project I made a couple of different flying shield prototypes. After some experimenting, I eventually reached a design that flew really well . . . and now I'm excited to share it!

I've included a PDF with all the pattern pieces that are required to make this. I worked directly from these finalized pattern pieces to build the finished version of the flying Captain America shield you will see in the following steps and in the video below.

The finished shield is 22.5" in diameter, and weighs 27.5 ounces (780 g). It's hefty, but it flies great. Still, you wouldn't want to knock a little kid in the back of the head with it, but it's certainly a lot safer for throwing around than this version (also made by me).

Here is a video of my flying shield in action:

Step 1: Things you will need

Here is what you will need to make your own Flying Captain America Shield:

  • Print-out of the attached PDF
  • Flat pieces of cardboard, at least 12" wide across the grain. I used thick double-ply cardboard.
  • Duct tape, one roll of each: red, white, blue, and regular
  • 24" of webbing or other suitable material for handles
  • 74" of 3/4" polypropylene rope
  • Cutting mat (I have a couple--I got a new double-side Alvin brand one, which is very nice)
  • Utility knife with extra blades (and/or heavy-duty hobby knife with extra blades)
  • Hot glue gun
  • Sharp scissors
  • Marking pen, like a Sharpie

In each step I will go into more detail about the materials and tools used.

when i try to open the pdf it wont, can you help?
Here's the file right here. If still you can't open it, it's a problem on your end. Make sure you have the latest adobe reader.
<p>colourfull duct tape not availablein india , what can i do \</p>
<p>Thanks for creating this project! Here's my effort, which will be my 2016 Halloween costume.</p><p>In addition to the hand grip straps, I added backpack-style shoulder straps so that I could carry the shield on my back. </p><p>(As I was fitting the shoulder straps, it occurred to me that this project could also be used to create a shell for a Teenage Mutant Ninja Turtles costume. Just use green duct tape and add shoulder straps.)</p>
<p>Excellent!</p><p>I love seeing that people are still finding this tutorial and making shields for themselves. Fantastic looking shield - I love the silver tape. Thanks for the photos! :)</p>
<p>I would like to make a tiny one for my 19 month old for his Halloween costume.. any suggestions for doing that? </p>
<p>I think you could actually just print the pattern at a smaller scale (from your print options window when you print stuff). </p><p>Then all the steps will be the same once you've got a smaller scale pattern printed. Good luck! :)</p>
<p>Thank you so much for this instructable. It took a little time, but so worth it. Can't wait for Halloween!</p>
I made this for my kids in the pediatric critical care unit in the General Hospital of Alicante, in Spain. They are very happy with it, thank you very much.
<p>Gonna use for a school project (More cost effective than steel diy alternative). I don't suppose there are 1:1 scale templates (30&quot; diameter), are there?</p>
<p>No, but you could certainly scale them up, in a variety of ways (either with photo editing, just printing the pattern at a bigger scale, or even by printing the template and using a copier to scale it up. A little trial and error is all that's needed, I'd say.)</p><p>Just shoot for the wedge pieces to be about 15.5 inches long, and that should get you very close to 30" total diameter when you're done.</p>
How thick should the cardboard be?
Um. I confused on how you drew on the duck tape and removed it from your table without ruining the duck tape. Can you explain it for me?
<p>Hi, that's a good question!</p><p>To pull the tape off of the cutting mat, I would use the tip of my hobby knife turned sideways to gently slide under a corner of the tape to lift it up. You can then gently pull the whole piece up.</p>
Can i use fevibond (rubber based adhesive ) instead of hot glue <br>
<p>Hi, </p><p>I'm not familiar with fevibond, so I can't say for sure. If it's all you have available, you'll have to try it out and see how it goes. Good luck! :)</p>
Do you think this could be adapted to sheet metal?
<p>I definitely think so. You'd have to have some metal working tools and quite a bit of skill though (neither of which I currently have!)</p><p>There are a couple of metal Captain Am. shields in this collection you might want to check out: </p><p><a href="http://www.instructables.com/id/Captain-America-Shields-and-More/" target="_blank">http://www.instructables.com/id/Captain-America-Shields-and-More/</a></p><p>Also this one:</p><p><a href="http://www.instructables.com/id/Copper-and-Aluminum-Captain-America-Shield/" target="_blank">http://www.instructables.com/id/Copper-and-Aluminum-Captain-America-Shield/</a></p>
<p>Hey. What size paper do you need? Is it A4 or A3 as my printer only does A4</p>
<p>Paper size will vary depending on what country you live in, but you can just print on whatever size of paper you have.</p><p>The paper I used was North American letter size (8 1/2" by 11").</p>
Can i do this with regular sized copy paper
<p>Yes, just use whatever paper you have :)</p>
<p>I used reflective silver instead of white Duct tape. However, the webbing I used for the straps are thin, and keep slipping out of the tape.</p>
<p>Heyy! I'm almost done with mine! Just need to add the last touches!</p><p>Here it is so far!</p><p>I plan for the 4th to add some glow stick rings to it to make it glow XD, they won't stay on but for the night it'd be awesome!</p>
<p>oh yeah. thanks a lot man for this tutorial!!</p>
Can we use any other glue<br>(Not hot glue)
<p>I used hot glue because it stays flexible. </p><p>I can't say what may or may not work as an alternate type of glue, but you can certainly try whatever kind of glue you have access to.</p>
<p>To say my son was thrilled was an understatement. Had to do a mini photo session after school today! Thanks again! &lt;3</p>
Time consuming but totally worth the effort! Just finished .. Can't wait for my son to wake up in the morning!! He's gonna freak out LOL
<p>That's a fine looking shield! Your son will be thrilled for sure. </p><p>Glad you found my little old captain America shield instructable and were able to make one. Thanks for the comment and photo! :)</p>
He was so excited this morning!! I'll be taking some photos over the next few days of him with the shield to share with you :)<br><br>Thank you so much for sharing your amazing instructions!!
<p>You bet! </p><p>Instructables is such a fun site. You should write up an instructable of your own sometime, to share the details of something you make. It's fun to share your work and connect with people, and the contests are a blast! </p>
Thanks! Will surely post a pic after shield is complete
<p>Hi its me again.</p><p>I just wanted to ask that will normal glue work instead of a hot glue gun?</p><p>In India the price of a glue gun is $60 so its expensive.</p><p>if not normal glue then what else can work?</p><p>Thanks.</p>
<p>Hot glue has the benefit of being flexible, so I'm not sure what other kind of glue could work as a substitute.</p><p>However, you could try simply taping each wedge of cardboard together, and skipping the glue altogether. That might work, but let me know how it goes. Best of luck! :)</p>
<p>Hi! Very nice method to make the shield! I am making it but I had a question.</p><p>Does it break or bend if it hits something very fast?</p>
<p>Thanks, glad to hear you're making one.</p><p>My kids stepped on it and sat on it (dome-side up), and I threw it into walls and stuff all the time. It always came back to the same shape, so I'd say it's actually super durable! :)</p>
<p>Excellent tutorial!! Thank you so much for sharing!</p>
This is the best thing of ever seen thanks for sharing this with the rest of the world you are an amazing person!!!
<p>Thanks so much for posting this! I'm about halfway through with covering it with duct tape (since it's for a costume, not to throw, I didn't use rope) and the center seems incredibly flimsy. Will that go away if I use another layer or two of tape or do I have to do something to reinforce it?</p>
<p>If it's super flimsy in the middle, you could cut out a 6 inch (or so) circle of cardboard and hot glue or tape that to the underside in the middle. That may work to reinforce it.</p><p>But that's just a guess though, as I can't say for sure why your shield seems flimsy. Mine was fairly rigid. Try a few things and see what works best. Good luck! </p>
<p>Thanks, I appreciate it!</p>
<p>Once i have printed everything and also cut it on cardboard, once i start to connect the first triangle parts , can i use masking tape or scotch tape on it? Because i do not have access to duct tape right now. Thanks!</p>
<p>I'm not sure masking tape or scotch tape will work, unfortunately. Duct tape is the only thing I know of that will work well for this.</p>
<p>could i use cloth tape?</p>
<p>That might work. Give it shot, and let me know how it goes! :)</p>
<p>to print out the pdf, do you need a3 paper?</p>

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Bio: I got an old sewing machine when I was just a kid, and I've been hooked on making stuff ever since. My name is ... More »
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