My son wanted a Nerf battle so I had to make sure I was equipped. After making this I know there were some things that I could have done better so please feel free to add any comment that may make it easier for others on their builds. Enjoy!
Step 1: Materials
• Mod Podge - others have used PVA
• Joint Compound - some type of plaster/cloth
• Paint - Flat White, Flat Black, Metallic Silver
• Round Head Pins
• Box Cutter
• Scubbing Pad
Step 2: Pressing
Trace the plexiglass on the 2nd sheet and cut out so the plexiglass fits tight and doesn't slide around.
Apply glue between sheets then add weight till the glue is dry.
(Not shown but I also added a window frame cutout to the front for looks - can see it in later pictures)
Step 3: Cleaning the Edges
I then used a surform tool to try and smooth the edging out as much as I could. I ended up using joint compound on all the edges to help it look smoother but now looking back I should have either used some paper tape or cut a long thin piece of cardboard and glued that on.
(you can see the window frame I placed on the front for looks)
Step 4: Bending Sides
Fill the channels with glue.
Bend in the sides and brace. As you can see I used some straps. You could also get away with tape if you don't have straps available.
Step 5: Handle
Seems to hold pretty well so far.
Step 6: Coating
Spread joint compound and sand smooth. I didn't put it on thick. The purpose was to make sure you couldn't see the grooves in the cardboard when painted. This is also the point if you want to put in any deep scratches or dings you could shape the compound.
2nd coat of Mod Podge. Thought this may help harden the paste and prevent chipping if anything hit the shield too hard.
(I left the plastic on the plexiglass so I didn't have to worry about taping off that area)
Step 7: Base Coat and Stenciling
Tape off anything you want to say or show white on your final product. You can project any images on the front and trace if you need to.
As you can see in the pictures when I cut out the skull I went too deep and ended up peeling off some of the paint and exposing the paste. This could have been caused by me adding Mod Podge on top of the compound.
Add pins around the plexiglass. Dip the pin part in some glue.
Step 8: Painting
Peel off the tape. Be careful you don't rip the white paint off here. Mine did lift so I used the Mod Podge again to make sure it stayed down and wouldn't peel up again.
Step 9: Adding Wear
I have also seen others use sandpaper or brushes.
Step 10: Final Touch
As I was doing these steps I would use some of the scrap cardboard as a test before actually applying.
At this time I have not finished the inside, but I plan to add felt cloth with spray adhesive then adding pockets to hold extra darts and clips.