Dagorhir is awesome. You think it's awesome and your new, but something you don't think is so awesome is everyone has shields. Some guy says he'll sell you a shield for $40 that he used for 3 years, but you don't wanna pay $40
for used gear like that. Soluton : A Safe shield made out of the good 'ol Wal-Mart stuff.
SUPPLIES
1- Ozark Trail Camping Pad
2- Straight Edge yardstick/Measuring Device
3- Leather Strap
4- Cutting Utensil ( I used an X-Acto with extra blades)
5- Duct Tape
6- Weldwood DAP Original Formula Contact Cement (You'll need something to apply it with, be creative)
7+8- Tee-Nuts and fitting bolts
9- Your Core, Mine is a 24" Diameter Circle NEVER Make your more over 27 inches wide since 3 layers around the edges adds roughly 3", so making it wider then 27" will make the final product over 30"( I reccomend 1/2" Plywood, and that's what I'm using)
YOUR CORE
I feel that it is important to measure everything so I don't screw something up. This method will be using many 1 inch strips, so I make a 1 inch grid on my core. I also marked the line every line down so I could get a feet for where my strips go
On the back side I draw out my arm, and draw a 2 inch line around the endes for where the back padding goes, and i select where i want to put my tee-nuts.(I'm not left handed it's just upside-down)
MAKING YOUR SHIELD
1 First thing that needs to be do is get your Tee- Nuts in place. For those of you not keen on hardware these are tee nuts and matching bolts. I used 5/16" x 3/4" Tee-Nuts from Home Depot. You can go to lowes but they are cheaper at Home Depot by like half price. It's close to $1.80 at lowes, but .97 at home depot! To use Tee-Nuts you drill a hole in the wood where you marked for where your straps will be bolted in. Once the holes are in turn your shield over to the face and put your Tee- Nuts in the holes with the spikes and cylinders pointing down. Hammer 'em in good.
When done right, flip over to the back side(Strap Side) and it should look like this: the main atvantage to using tee nuts over standard nuts is you can remove the straps whenever you want and the nut will still be there to put the bolts back in, and you don't even have to have your straps done before you make the shield. You just have to put the nuts in. Make sure your tee nuts are spikes going Face side into the Strap side, becuase if you have it backwards so the spikes are dug into the strap side, you will rip it out when you use the straps.
FOAM You need to get alot of 1 inch strips. Alot. Not a whole camping pad of strips, but alot of strips. This design uses alot of strips. Once you have your strips (I'm assuimg you know how to use the DAP) Glue it on one side, then glue every other line type area on the grid. either horizontaly or verticly, it doesn't matter which as long as you alternate the direction for the second layer. When putting on the strips make sure that it goes over the edge, or exactly flush with it. When it goes over the edge, trim it to the shape exactly. After that, do the exact same thing in the other direction (Horizontal or Vertical) so it should look like this: Don't mind the small naked vertical spot, i patched this up, but couldn't take a picture becuase I put the solid layer on. Don't leave gaps, make sure all the are is overed ixcept the 1" squares that shouldn't be (Like in picture)
After that you need to put a solid layer on the top. I glued the entire solid part becuase I couldn't work out where the lines were, but only glue the top strips on the wafle, glueing the wood or bottom ones is unessecary and will just add weight. I put the shield down a camping pad and just trace it. Depeding on size multiple peices may need to be used. Put a strip of duct tape over and seams. Put it under wight over-night and work on the rest another day if applicible.
Once the glue is dried cut a two inch strip of foam and glue it around the edge on the strap side, like illustrated by the line earlier. I add the foam that goes behind your strapped in arm during this step too. I don't measure out my straps before this step either. making straps is just trial and error seeing what length fit on your arm. I hate washers so i wrap the ends of my straps in a good length of 1/2 wide strip of duct tape, and I've never had a ripped strap doing that. Drill a hole to put your bolt through, and bolt them down. Keep in mind the foam that goes under your arm, if you don't add it in your straps may not fit.
After the strap side is done you need to cut out 2.5" wide strips and glue them to the edge of the shield, going around the entire edge. You may need to trim them to be flush with the front and back padding. Make ATLEAST 3 layers around the edge, no questions asked. Once your 3 layers around the edges are on, you're shield is done! I recommend you let verything dry a day before you go using it, so it doesn't fall apart. Now it only needs a cover. I get some cloth and pull it even on the face then just staple it around the edges and trim off the excess, but that's becuase I can't sew.
Guide by Div of A.D.D.
Design was something I heard from Olaf, not certain of actual inventor. If you made the design and want credit contact Dzanman@Gmail.com