Introduction: Making a Captain America Shield Out of a BBQ Grill

Picture of Making a Captain America Shield Out of a BBQ Grill

I found a tabletop BBQ grill at ACE Hardware and immediately thought of Captain America rest in peace. This requires nothing more than sanding, epoxy, and paint!

Step 1: Find BBQ Grill!

Picture of Find BBQ Grill!

At ACE Hardware, I found a Marsh Allan Tabletop BBQ Charcoal Grill for ~$10. After buying this, I unwrapped it and laid out the pieces

Step 2: Sanding

Picture of Sanding

The first thing to do is to sand as much as possible so you have a rough surface to affix paint to. I took a sanding block and went over as much as I could with the coarsest sandpaper I could find. I then took a can of KILZ spray primer and gave it two or three light coats.

Step 3: Print Out Picture

Picture of Print Out Picture

I printed out a picture of the Captain America Shield and picked out the blue and red paints I planned on using for the shield

Step 4: Red Coat

Picture of Red Coat

After the shield is completely dry, I followed the ring edges on the BBQ grill to paint it red. The outside ring of the grill was all red, and the middle ring too.

Step 5: The Star

Picture of The Star

Using the image from before, I blew up the star in Adobe Photoshop and cut it out. I then rolled thin pieces of masking tape and lined the edge of the star. Once that was done, I placed the star in the center and painted blue paint right over it.

Step 6: Paint Touch-ups

Picture of Paint Touch-ups

After removing the star, I noticed some of the blue paint had seeped underneath. I scraped the excess blue paint off with an Xacto knife and touched up the areas that needed extra coats.

Step 7: Handles

Picture of Handles

After I gave the paint a day to dry, I sprayed it with about 3 coats of clear coat. Once that was dry, I went back and mixed up some 6-minute epoxy. This was spread on the edges of the handles then set. One was placed in the middle of the shield to put your arm through, and the other was placed on the edge to grip.

Step 8: Enjoy!

Picture of Enjoy!

Now your Captain America shield is complete and it's time to fight crime on the streets!


Ben DangerH (author)2017-02-21

Great idea,

AUGUSTO VJ (author)2016-08-11

Its really a wonderful idea!!

DetGamble (author)2011-09-28

Awesome work, I'm going to have to try this out.

superdober (author)2011-08-08

used same steps u did for my shield. except i used an aluminum trash can lid and used one of the handles for the grap and the one for the arm was a cut up leather belt

hoobs55 (author)2011-07-15

awh, shame that Cap wields his shield on his left arm, but great ible [:

b0bman (author)hoobs552011-07-23

maybe it's 'bizarro' cap? lol

Hoaxinmi (author)2009-08-27

nice. I was thinking about making one out of those circular snow sleds. Think this would work?

BAKEMASTER33 (author)Hoaxinmi2010-12-21

It would defenitly work I did the same thing except made a spartan shield (school project) out of a plastic sled turned out great.

Sandisk1duo (author)2008-07-05

Isn't that a Wok? Chinese food is prepared in those! Great Instructable though!

smithn (author)2008-01-21

Hay this is pretty damn cool, screw what others say I would never of thought of this. I'm going to have to make this now.

snipeyouout (author)2008-01-01

sorry let me rewrite that, theres some things you don't have to tell people how to do, this is one of them

your kinda repetative

I have no idea what you're talking about.

snipeyouout (author)2007-12-29

theres son thing you just have to tell people how to do,this is one of them, no hard feelings


snipeyouout (author)2007-12-29

some things* and don't have tohow to do sorry

craig1st (author)2007-12-24

Allow me to say, great shield. Actually, it's nifty! I was thinking that a large spun wok cover with the handle reversed would also work well. Or, an actual steel wok for a full function version!

AdrenalineSpeed (author)craig1st2007-12-24

they make woks that big?

craig1st (author)AdrenalineSpeed2007-12-25

Big woks are ubiquitous over in Asia. I've seen commercial ones at least four feet in diameter. Here's one you'd not have to look far to find in any South East Asian marketplace:

Here in northern Cal, a trip to the SF or Oakland China Town would probably yield some likely candidates. Just look for a restaurant supply shop.

DonTron (author)2007-12-24

Hi, its me, Don Hersey, with a photo of the paint I was discussing, in action. McMaster's commentary on the paint: "Rust-Stopper Water-Based Paint— Stop rust from starting and prevent existing rust from spreading with this high-quality, low-odor paint. It also offers resistance to mild chemicals. Use it on steel, galvanized steel, aluminum, wood, concrete, and masonry. USDA accepted. This paint can be applied directly to metal surfaces, except for abrasive-blasted steel and aluminum, which require a primer. Note: Not VOC compliant in all areas. VOC content is 250 grams/liter for paint and primer." The substrates illustrated here are perf bar from the big-box vendor Menard's, and a length of blackened structural steel tubing from Metal Supermarket. Both were soaked in a solution of TSP substitute and scrubbed with stainless-steel-wool and dried before application of the paint. This is in the context of the quotidian application of a homemade shelving unit, not as nifty as a Captain America Shield, but adequately illustrative, I hope.

AdrenalineSpeed (author)DonTron2007-12-24

Hey Don, I'm only 20 years old, haven't had much workbench time playing with different paints yet, but i've been looking for one that resembles a powder coat. If you do try the shield, please keep us posted.

Marinus84 (author)2007-12-23

Maybe a nice idea to put the 'grip' bars on the shield before painting, so you can overpaint the screws, or other material that was used to attach the handles.

ah, 6 minute epoxy was used, so there is no sign of attachment on the front. If you did want to bolt it on, I would attach the handles before paint.

Hehe, excuse me, i was thinking in my own box :-) You're right, Epoxy would do it also. I was thinking about using a pin that is pushed through another pin that extrudes to make is lock tight. (Push pin? I don't know since i'm Dutch, it's called 'popnagel' literraly translated to 'popnail')

Ah I believe you're talking about a rivet. A rivet would do nicely, and would be barely noticeable too.

You're right, i mean this type:<br/><a rel="nofollow" href=""></a><br/><br/>It would maybe give it a more 'mechanical' look (if not painted)<br/>

Good call. I'm eager to see how your shield turns out with the rivets, keep me posted.

DonTron (author)2007-12-22

I got this paint from McMaster-Carr, its water-based anti-rust paint from Rust-Oleam that comes in the 'safety colors.' Mine was blue, and worked great! I don't think it is good for Al, but works nicely on Fe and pretty well on Zn, I'm sure it would work great on this project. I recall it ran for about $20/gal. If you stir it well and apply it in two thin coats, it appears almost like powder-coat!

AdrenalineSpeed (author)DonTron2007-12-22

sounds great, give it a shot and post pics!

howboutitbru (author)2007-07-14

he died? when how what

From Wikipedia: "Captain America is indicted on multiple criminal charges. As he is brought to a federal courthouse, a sniper shoots him in the back. In the crowd chaos that ensues, he is wounded an additional three times by gunshots to the stomach and chest. Rogers is taken to a hospital, where he dies." The assassination, orchestrated by the Red Skull, involves Crossbones deployed as the sniper. In addition, Dr. Faustus, posing as a S.H.I.E.L.D. psychiatrist, gave Sharon Carter a hypnotic suggestion she believes caused her to shoot Rogers at a crucial moment."

Wasnt there something about him coming back. I thought I heard something on TV.

what a beast

im tlaking about the capt. here

Devin Jax (author)2007-08-14

very creative on a way of creating caps sheild.I'm also a great fan of CAPTAIN AMERICA!!!!

MidiaN_76 (author)2007-07-12

Sweet shield!

CementTruck (author)2007-07-11

Great job. A snow disk/saucer would have had the curvature for this shield too. I wonder how they're going to resurect poor Cap? You know he isn't staying down!? My guess, nanobots, or nanotech. Are you gearing up for Halloween, or ........ Never mind, I don't want to know. What you do on your own time, behind closed doors....... ;)

oooh a snow disk! Damn why didn't I think of that. That would be perfect for the Caps shield. I usually mod computers, not BBQ grills...

mrmath (author)2007-07-11

A moment of silence for the passing of this great Nazi/Commi fighting hero.

mikesty (author)2007-07-11

Might I be the first to say: OMGWTFBBQ! Cool find :)

Tool Using Animal (author)2007-07-10

MAN!!!! I Loved Captain America, sweet.

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