Instructables
Picture of How to make a Buckler out of Sheet Metal
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I decided to make a buckler out of sheet metal for one of my friends who is very interested in Monster Hunter, a Action/Adventure/RPG that involves fighting massive monster with awesome weapons. This is the start of one particular sword and shield from the game.

Materials:
          18"x18" 18 gauge sheet metal
          18"x18" poster board
          2 strips of sheet metal 2-3 inches wide and about 8 inches long. I used 18 gauge again.

I made this using a variety of tools at Techshop RDU. Awesome place would seriously recommend going at least once.

I also just finished a Helmet that goes with this seen here.
 
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Step 1: Plan it out in Correl Draw

Picture of Plan it out in Correl Draw
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Really simple step. Draw a circle of the outer size of the shield. If your circle is bigger than the size of your laser printer then just print it on 2 or 3 sheets of poster board. Then draw another circle that is the size of the boss. I used 18" and 10" for my measurements. Make the outer circle hairline and the inner circle as dashed then set the thickness to something like 8-10 pt.  This will allow you to have a cut out big circle with a smaller circle you can see on the metal. Here are pictures of the laser in action, and the final template.
flamesami1 year ago
Like brianhunt said, the end product is nice, but not historically accurate, but unless your mate is going to do actual combat, it doesn't really matter, it's a nice prop.
Also, the sandbag goes underneath the bit to be dished while it's being hammered, right? So you have a giving surface to hammer into?
rimfire13 (author)  flamesami1 year ago
Correct, I was trying to raise the dome. You set the sandbag down then hammer in a spiral towards the center spreading the inner material to the outside raising the edges and hammering the center down. Again I was modeling this after a video game shield, so obviously not historically accurate, but thank you for the concern. Also the use of powder coat, a sandblasting cabinet, a laser, and a pneumatic planishing hammer would obviously detract from the product if I was going for historically accurate. Sometimes i’ll make something historically based, in which case I will attempt to use historical tools, this was not that type of project. Thank you though for your comment.
brianhunt1 year ago
Just a quick note. You have done a very nice piece of metal work there, but as a teacher of medieval sword and buckler I think you might like to know that a buckler is held by a center grip like a viking round shield. Otherwise, good job. For additional strength you might want to roll the edge as well. All the best.
I was going to say that too! :) it is a good job, in spite of historical errors
I like it. Really I like anything that gets people, who otherwise wouldn't, to consider working with metal.

Now, I don't know anything about bucklers or armory in general but why go through the bother of drafting a template onto paper? I would think that a compass or a divider ... or a 5" and 9" stick with a nail at each end would give you the concentric circles you need.

I like your use of the planishing hammer, probably could have started with that but it makes for a better tutorial since a lot of folks don't have access to the air rig. The powder coat is a nice touch. I work with copper and brass so I never bothered with it but it sure makes for a nice finish.
rimfire13 (author)  ArtificerMade2 years ago
Thank you. I just decided to use the tools I had available at techshop. Hopefully my templating idea inspires someone else to make something more complex but using the same method. Thank you for the message though, it means a lot. I’d love to see some pictures of stuff you’ve made from metal. (Your instructables are fantastic by the way, I just looked at a few)
Awesome! I bet it would look great in a bronze color, too. :D