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Flying Captain America Shield

Flying Captain America Shield
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:


 
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Step 1Things you will need

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
  • 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.
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157 comments
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Jul 19, 2011. 8:17 PMIron-Man227 says:
I started my shield yesterday and finished it this night and it is awesome! I must say this is an awesome tutorial that is clear and forward with everything from the materials to what needs to be done. The only thing I had a problem with was laying down the white circle so instead of "eyeballing it" lol I chose to mark off certain points to make it even but here is the finished product.
Jul 19, 2011. 9:09 PMIron-Man227 says:
Thanks! Yeah as soon as I saw this I knew I was going to make one for the movie lol and also I am going to make one for my cousin, though he is smaller, he can grow into it and can still have fun with it.

I still think yours is better lol I don't know what it is it just looks cleaner. I will say I have one problem that when I put the cardboard shield together it started dipping in the middle, I thought I could fix that with the duct tape part but it is still doing it. Any thoughts on what I could do to push it out and make it stay out?

Thanks! Yeah I layed them all out and tried at least four times but could not for the life of me get them to make a nice ring. So I measure from the blue circle out 2 /12 inches on each line where cardboard met and made a mark and it helped tremendously! Thanks for using an idea!
Jul 19, 2011. 9:30 PMIron-Man227 says:
Hmmm I think that I may have bent the individual pieces too much I don't know but it's not that big of a problem and it's my first shield so I knew that it wouldn't be perfect but it's close. I am going to try putting it on something pointy or with a tip to push the center up and leave it like that for the night. Also that is pretty crazy how it will still pop back into place even though they beat it up so much.

Well thanks again for the help I will get back to you with the dip see if what I do helps it, as well as my 2nd and 3rd shield I plan on making!
Jul 21, 2011. 4:42 PMedlalmaraz says:
Here is the final Product. It isn't as good as yours, but it was pretty good.
Jul 22, 2011. 2:55 AMjbrowning says:
Made mine in time for the movie Not as good as your but I think next time double ply is a great idea
Jul 23, 2011. 10:28 AMaidanjmac says:
Great tutorial! I replaced the white parts with silver like in the movie, which I was worried wouldn't come out well, but I'm satisfied with the result.
Jul 23, 2011. 8:36 PMaidanjmac says:
I used silver coin "Duck" Tape, which I got at A.C. Moore.

http://www.acmoore.com/p-99391-colored-duck-tape-188-wide-20-yard-roll-silver-coin.aspx

Regular duct tape would be a little too gray, I think. Unfortunately, if you rub the silver coin tape too much the silver rubs off and the tape turns gray. But you can always replace it with more tape.

My friends got a big kick out of the shield, especially throwing it. Holding the shield out of a car window and yelling "CAPTAIN AMERICA!" at passers was pretty entertaining. Have you thought about making any other Avenger-related props, like an Iron Man helmet or Thor's hammer perhaps?
Jul 24, 2011. 6:19 AMaatkinson3 says:
I noticed that my center would dip down, too. Then I realized I had one too many wedges in the dome. I took one out and it popped into place and had a good, sturdy dome-shape. So, count your wedges...make sure there are only 20.
Jul 24, 2011. 6:29 AMaatkinson3 says:
Here is the finished product. This was an awesome project. My son loved working with me on it and he is quite proud of the finished product.
Jul 24, 2011. 8:23 AMIron-Man227 says:
Hmm that's a good point, but nope I have 20 pieces and my new dholes doesn't really dip though it does a little I don't know what I'm doing wrong. It's not horrible but just slightly annoying lol. What I did with the new shield was after I put the two quarter sections together for each half, I flipped it on it's front and layed it down flat to help and it did and then it started to dip a little. I'll post a pic later of the two dips. Like I said it is not a big problem just a small thing that bothers me.
Aug 15, 2011. 7:28 AMdublek says:
Well, I finally got my shield finished! I could only work on it for a little while at a time, before work, and had to start over once, but here it is.
In my first attempt I didn't get enough curve to the segments and when I went to draw the last section in to glue it together the center popped up so it was more of a shallow cone than a parabolic curve....looked more like a coolie hat than Cap's shield.
Anyway, it's a fun project and I'm thinking of all kinds of modifications I can do to my next one, like scaling it up a bit, using metal tape instead of white like some of the others here have done,etc. Might get brave and try coating the cardboard with resin and fiberglass cloth then sanding it to shape and painting it using your technique from your satellite dish shield.
May 22, 2012. 10:09 AMKISSfreak says:
i think mine turned out pretty decent! :D
May 21, 2012. 6:56 PMKISSfreak says:
heres mine
May 20, 2012. 11:37 PMnoahpoitras says:
It will not let me download the whole PDF
May 1, 2012. 5:00 PMStaufer says:
How much cardboard?
Apr 29, 2012. 9:51 AMkpagapong says:
I made one today. Though I didn't use duct tape for the details. I used palara paper if you're familiar with it. It's not as good as the one you've made but I really like the "shiny" effect. I used a belt for the handle so that you can adjust it. :))
Mar 6, 2012. 6:21 PMangelheart23 says:
THANKS for this GREAT and detailed tutorial. My hubby and I made this shield for my boy's school event. My boy LOVES it.
Mar 6, 2012. 8:53 AMCaptHollis says:
Me and my mom worked together to build this over a weekend. Thanks for the brilliant instructions!

Here's my shield:
Dec 19, 2011. 11:58 AMSnappleNpop says:
This was by far the best part of my costume, I love it so much. Thanks again for the wonderful tutorial! I also but to set of straps inside, one for sliding it on my arm, the other to sling around my back. I can post pics if anyone wants to see that.
Nov 20, 2011. 7:04 AMAgentHomemade36 says:
I will start making mine when it's X-mas break. I've got some of the stuff I need. I want it to be as perfect as your's. It's awesome. Oh, do you think you can make the movie helmet or something?
Nov 16, 2011. 7:24 PMrobojo says:
Add one more to your list. I made one today.
Nov 5, 2011. 12:39 AMdakata1 says:
Thats the shield I made:
Nov 3, 2011. 2:51 PMMainFrameNZ says:
Awesome Instructions, did this when I had time with my son. Took loads of cloth tape to make, but worth it. My son and I love the results.
Oct 19, 2011. 9:22 AMSnappleNpop says:
Thanks for the great instructions. I ran into a small problem however, and was curious if anyone else did something similar and how they might of fixed it. After I cut out my 20 pieces and assembled them in quarter slices, I can't the tips to touch therefore making a small opening in the middle, causing the dome to cave in the middle. The stencil pieces look all right, should I cut out another 20 and try again? Or is there a trick to what I am doing wrong? I actually cut out 40 pieces and hot glued them together since I could not find double ply, but I followed the same stencil for all the pieces. Any help is much appreciated, thank you.
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