Making a Captain America Shield Out of a BBQ Grill

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Introduction: 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!

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

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

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

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

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

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

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!

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

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    41 Discussions

    Its really a wonderful idea!!

    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

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

    1 reply

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

    1 reply

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

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

    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.

    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!

    2 replies

    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:
    http://www.flickr.com/photos/43334420@N00/332375843/

    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.

    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.

    BlueMetalPaint.jpg