Instructables
Picture of Flying Captain America Shield
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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:


 
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Step 1: Things you will need

Picture of 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.

Step 2: Cut out pattern pieces

Picture of Cut out pattern pieces
Begin by printing out the attached PDF from step one. It will be easier to use the pattern pieces if you print this on a heavier paper like card stock.

Carefully cut out each of the pattern pieces using either a sharp blade or scissors. Use tape to join the two sections that form the larger wedge-shaped piece, as shown in the photo.

Step 3: Cut out cardboard wedges

Picture of Cut out cardboard wedges
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The shield is made up of 20 individual cardboard wedges that are curled slightly, hot glued together, and then covered with duct tape.

The large wedge-shaped pattern piece labeled "SHIELD" is used to create all the individual sections of cardboard that go together to make the shield.

Trace this pattern piece onto cardboard 20 times, being sure the grain (or lines) of the cardboard run across the narrow width of each wedge-shape.

Use a utility knife with a new, sharp blade to carefully cut out all of these pieces. A sharp blade and cutting mat are a necessity for this step.

Work slowly, be careful, and watch your fingers.

Step 4: Gently curl each shield piece

Picture of Gently curl each shield piece
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For the shield to end up in a slight dome, you will need to gently curl each wedge-shaped piece.

Use both hands to pull each piece over the sharp edge of a table, which will "break" the stiffness of the cardboard. Your curled pieces should be similar in shape to the ones shown in the first photo.

Step 5: Tack together quarter-sections of the shield

Picture of Tack together quarter-sections of the shield
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Use hot glue to tack the shield pieces together. You don't need to use a ton of glue, as you will be adding plenty of tape later on which will solidify and strengthen the shield.

I recommend beginning by assembling quarter-sections of the shield. This will make it easier to keep things lined up and ensure that the completed shield comes out round. (If you add one piece after the other all the way around the shield, the pieces tend to drift or "creep," and you may not end up exactly where you started.)

Each quarter-section will have five pieces in it. Begin by gluing two pieces together, and then adding the third, fourth and fifth. You don't need to glue the full length of the seam between each two pieces--just the top and bottom couple of inches will do. The most important thing is that the outer edges of the pieces (which will be the outer perimeter of the shield) are lined up evenly.

You will need to gently adjust the curve of each of the pieces so they mate up nicely with each other. There will be small gaps, especially on the top portions of the shield, but this is okay.

Step 6: Join the quarter-sections

Picture of Join the quarter-sections
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Once you have all four quarter-sections completed, you are ready to assemble the final dome-shape. You may notice that the four sections are not quite 90 degrees, as you might have thought they would be. Don't worry, this is correct and everything will fit together nicely.

Begin by joining two sets of quarter-sections so you have two completed halves.

Now join both halves. This may take an extra set of hands to hold them together while the hot glue cools, since the two halves will naturally want to pull apart. This is where the dome takes it's final shape, as you force these two halves together.

You should now have a "naked" Captain America shield. You're half-way there!

You'll be tempted to take it outside and try to throw it. Don't do it. Resist the urge!

Step 7: Reinforce backside of shield

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Use strips of regular duct tape to reinforce the seams between the glued sections on the backside of the shield. Make sure you press down firmly so the tape sticks well.

Step 8: The secret to making it fly...

Picture of The secret to making it fly...
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A length of suitably heavy rope needs to be added to the underside perimeter of the shield, which is the trick to making it stable enough to fly like a Frisbee. It also provides a nice lip for looks, as well as a place to grip for throwing or catching.

You will need about 74" of 3/4" polypropylene rope, which can be purchased by the foot at most hardware stores.

To keep the rope from fraying when you trim it to length, wrap a few inches of tape around the cut ends. You could use a lighter or torch to fuse the ends as well, but it will all be covered with tape soon enough, so it's probably not worth the effort.

Use hot glue to firmly glue the rope down along the underside edge of the shield.

Step 9: Cover the edge with red duct tape

Picture of Cover the edge with red duct tape
Use 6- or 7-inch strips of red duct tape to tape over the rope and edge of the shield. Try to keep the tape as tight up to the rope as possible so there aren't any big air pockets along the inside lip of the shield.

Note that for all pieces of duct tape that you use from here on, you will want to cut them off of the rolls rather than tear them off. This will help keep things clean and neat. This is where a sharp pair of scissors comes in very handy.

Step 10: Cover backside of shield

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Cover the backside of the shield with strips of regular duct tape.

Try to be as efficient in covering as you can in order to keep the weight down, but make sure every bit of cardboard is covered.

Step 11: Attach handles

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You have some options here.

I had some 1 1/2" webbing that I salvaged off of an old gym bag which worked very well as handles for my shield. If you have some 3/4" webbing, that would work equally well. You could also just as easily fashion some handles out of a few layers of duct tape.

Whatever you choose, cut two strips of your material about 12" each (add a little more if you have bulky forearms). Hot glue the ends down, positioning the handles similarly to what is shown in this photo, and reinforce all around with more duct tape.

Step 12: Cover top of shield

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Cut strips of red duct tape and cover the top of the shield. Try to keep everything as smooth and wrinkle-free as possible.

Step 13: Add center blue circle

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The pattern piece labeled "CENTER CIRCLE" is used to draw out the shapes that will be used to make the center blue circle on the shield.

Lay out three 24" strips of blue duct tape, overlapping each piece about 1/4", similar to what is shown in the second photo. (I initially only laid out enough blue tape to draw out 6 pattern pieces, so I had to do this part twice.)

Trace the pattern piece 12 times onto the blue tape, and use a sharp hobby knife or utility knife to cut out the wedge-shapes. When you pull them up off the cutting mat, be sure to pull them up starting with the layer of tape that is on the bottom. This way the separate pieces of tape that make up each wedge will all stay in place.

You should be able to see where the exact center of the shield is, based on where the cardboard wedges meet. If you can't see this through the layers of tape, squish the tape down with your fingers to feel where the center of the shield is. Make a mark or poke a small hole with a pin if you need to, to use as guide to help you place the blue wedge-shapes in the center of the shield.

Step 14: Add white ring

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The white ring is made from white duct tape, and is completed in similar fashion to the center blue circle. 

Trace the pattern piece labeled "WHITE CIRCLE" 8 or 9 times onto two strips of white duct tape, as shown in the second photo.

For placement of the white ring on the shield, I just eyeballed it. The goal is to have three rings of equal width (red, white, red). If it looks funny or crooked, you can always pull it up and re-do it.

A more precise method would be to use a ruler or measuring tape to place a few marks around the shield from the center point to aid in the placement of the white ring. The inside edge of the white ring should be placed about 7 1/8" (181 mm) from the center point of the shield. (Thanks to Iron-Man227 for this tip!)

Step 15: Add center star

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The center star is completed similar to the method used in the last two steps, using the pattern piece labeled "STAR" to draw out the five sections that make up the star.

When the shield is held level on the left arm, the star should be pointing up. Place all the star pieces accordingly.

Step 16: Clean up the shield, and you're done!

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A little bit of denatured alcohol on a rag will quickly clean off any marker lines left over from tracing your pattern pieces, and will leave your shield looking slick and shiny.

That's it. You're done!

It may take some practice to be able to throw it well--if you have a hard time throwing a Frisbee, you may struggle with this. Practice with a regular Frisbee if you need to, and work your way up to your awesome homemade Captain America shield. Remember to whip your wrist as you release the shield, to give it plenty of spin.

I'd love to see some photos of your finished shield if you make one. Just upload a photo or two and post them with a comment.

Thanks for checking this out. Go Captain!
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when i try to open the pdf it wont, can you help?
seamster (author)  Kurohitsujii1 year ago
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.
TBrickman5 hours ago

dude nice you were my first commenter on my crossbow!

LanYamato made it!12 days ago

I really appreciate what you made thank you so much :D It took me a while to make this. I wanted to do this since the first movie came out but I was busy with school work. I've made mine with silver duct tape for the movie effect and separated the star pieces a bit to give it more of a look also panel lined the shield. It's already warped due to excessive play hehe I was thinking what other materials can you put in the shield to make it more durable? A thought I had would be to make 2 or 3 cardboard shields and lay them on each other with the seams alternating would that be feasible? Again thanks for this wonderful work! :D

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seamster (author)  LanYamato11 days ago

That looks great! One of the best I've seen, I think.

You could definitely make additional layers of cardboard. Each additional layer underneath the top one would stick out a little, so you'd have to trim off probably a couple centimeters all around. Don't know if it would fly very well, but I'm guessing you're going for more durability rather than fly-ability!

Glad you posted the photo. Thanks!

Yeah hahaha am also considering some rubber foam though I never really worked with that stuff. It was just suggested by my friends who cosplay. Well we throw it by the strap :D The fly-ability issue with the added layers won't be a problem I suppose since we have momentum and such :). Also thanks for the trimming tip on the edges!

middle0071 month ago

is it better to stick all the triangles together then bend them so you have all right or do it your way and could have some pieces bent differently.

seamster (author)  middle0071 month ago
You need to curve them first, then glue them together. You won't get the correct dome shape if you glue them together first. Good luck! Let me know how it goes.
irontom531 month ago

thinking of altering youre method to make a wooden shield ...im thinking about just doing the triangle pieces of the base out of a thin board then sanding circularly to give the movie brushed effect provided I can bend the board haha will keep you updated

seamster (author)  irontom531 month ago
Cool idea. Give it a shot, and let me know how it goes. Good luck!
jmaduro made it!1 month ago

Just finished it today:) it was really fun to make!! Thank you Seamster for this cool instructables.

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seamster (author)  jmaduro1 month ago
Looks great! Glad you found the pattern and were able to make one!
Enchanting_ELK made it!2 months ago

Thanks so much for this! Here's a photo of me the other weekend as Captain America with an Iron-Man! Unfortunately I ran out of silver and red tape the night before, so with the red I had to remove some of the extra that'd be unseen and reuse it for the middle circle :'D and used paper for the white circle! I'm going to complete it properly when I get some more silver tape haha. I also added a strap so that I could carry it on my shoulder! c:

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brose9 made it!2 months ago

This worked so well! I got so many compliments from people at the con. Only took me a week whenever I had free time :) thanks for the awesome guide!

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seamster (author)  brose92 months ago

You're welcome! Glad you found it and it worked for you. Thanks for the photo! The rest your costume looks great, did you make it?

Finally! It took my two days to do This for my Final project. A+, here I come!!

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Awesome! Glad you were able to make one.

I've been assigned my final exam project for my AVID class. Were supposed to teach our tutorial group on how to make something. That's when I found this webpage, this shield looks so cool! I'm having trouble finding the appropriate cardboard though. Even though I have all the other materials listed. Where can I find double ply cardboard?

Many shipping boxes are a thicker type of cardboard that would work well. I'd check with a local grocery store and ask if they have any cardboard you could have. But in reality, most basic cardboard would work fine.

Is it mandatory to use card stock paper for the printout?

No. I just suggest that because you will cut out the pattern pieces and use them as templates which you will have to trace over and over. The pattern pieces will hold up better and be easier to trace if they are made of something a little sturdier, like card stock.

You could just use regular office paper, but it's harder to trace repeatedly. Another option would be to transfer the initial printout pattern pieces to something a little stiffer, like cardboard from a cereal box.

ok, what I've been doing is just using the template once and then use the card board to repeat the shapes

Ok, thank you!

cristoph2 months ago
I'm using just the shield template for a spartan 300 shield
RoyalWeirdo3 months ago

How big should the print out be?

seamster (author)  RoyalWeirdo3 months ago

Hi! Just print directly on standard 8.5" by 11" paper. If your print software has the option "no scaling" (or a similar phrase), you may need to select that. But generally, you can just open up the file and hit "print" and it should work. Good luck, let me know how it goes!

Topzmad3 months ago

I am 14 and dont have access to tools like this, and cant get any diffrent color ducktape. Do you have any other methods that i could use?

seamster (author)  Topzmad3 months ago

Hmm. I'm not sure of any other methods you could use. You might be getting to that age where you can get a little job, save up some cash, and buy yourself some supplies. In fact, you might be able to track down a lot of the stuff you need for free. Just ask around.

I'd recommend starting with a small cutting mat, an exacto blade, decent scissors, and a glue gun. These basic things will open up a lot of creative possibilities for you. I started gathering stuff like this when I was about your age, and put all my stuff in an old fishing tackle box, which I still have 20+ years later!

mstubbs33 months ago

I've just made this. gonna test how well it flies later

themasterman3 months ago

I'm using silver Duck Tape it looks much more real

seamster (author)  themasterman3 months ago
Nice! Post a photo when you're done with it. I'd love to see how it turns out.

A lot of people have opted to use silver tape instead of white. It does look pretty awesome, and matches the version of the shield in the movies.
zeroglory4 months ago

Has anyone tried coating the shield with a clear epoxy to make it harder/more durable?

cryophile made it!4 months ago

I just finished mine! It only took me a few hours spread out over a week or so. It seems to have a rather limited range; perhaps I am throwing it wrong?
P.S. Kilroy was here. ;)

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seamster (author)  cryophile4 months ago

Hey, looks great! Maybe practice will help you throw it farther. Thanks for the photo. I'm glad you were able to make one!

sarahmon90 made it!5 months ago

Love it! I was able to make this in an afternoon, and it went together easily. Now I just need to add a strap so I can wear it on my back. ;)

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seamster (author)  sarahmon905 months ago

Nice work! Glad I could share the pattern with you. Thanks for the photo!

how do you put the handle strap things on?

how do you put the handle strap things on?

I've been waiting for a flying captain america shield and this is the one for free

FYI, here is one of the shields I gave away at Christmas. His dad made him a plane last year, painted in the Captain America totally by coincidence!
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