Crafting Your Own Defense: A Detailed Guide to Making a Wooden Shield

For centuries, the shield has been a symbol of protection, strength, and martial prowess. Beyond its functional role in combat, a handcrafted wooden shield carries a unique sense of history and personal accomplishment. Whether you’re a historical reenactor, a cosplayer, or simply a maker looking for a challenging and rewarding project, building your own wooden shield can be an incredibly satisfying endeavor. This comprehensive guide will walk you through the entire process, from choosing the right materials to adding the final finishing touches.

Understanding Shield Types and Construction

Before diving into the crafting process, it’s important to understand the different types of shields and their basic construction. Here are some common shield types you might consider:

• Round Shield (Buckler): Small, light, and maneuverable, often used in one-handed combat. Historically, they ranged from small bucklers used for parrying to larger shields that provided more coverage.
• Kite Shield: A teardrop shape, popular in the medieval period. They offered good coverage for the body and legs while remaining reasonably light.
• Heater Shield: A more rectangular shield with a rounded top, favored by knights and infantry in the high medieval era. It provided excellent coverage and was often emblazoned with heraldry.
• Viking Shield: Typically round with a central boss, these shields were often made from multiple wooden planks joined together and covered in leather.

While there are many variations, most wooden shields share a few basic construction elements:

• The Base (Shield Board): The main wooden structure that provides the shield’s shape and size.
• The Boss (Umb): A metal (usually steel) dome placed at the center of the shield. It protects the hand and offers added strength.
• Reinforcement: Metal bands, leather or other materials used to increase the shield’s structural integrity and prevent cracking.
• Grip: The handle or grip on the inside of the shield that allows it to be held and maneuvered.
• Facing (Optional): Leather, rawhide, canvas, or other material that covers the wooden base for added protection, aesthetics, and water resistance.

Materials and Tools You’ll Need

The following is a list of materials and tools you will need for the construction of your wooden shield. This list is comprehensive and some items might not be needed depending on the specific style of shield you plan to create.

Materials:

• Wood: The most important material for your shield. The type and thickness of wood will affect the shield’s durability and weight. Good options include:
• Plywood: Strong, relatively inexpensive, and comes in various thicknesses. Good for beginners.
• Hardwood (Oak, Maple, Ash): More durable but more expensive and harder to work with.
• Softwood (Pine, Fir): Lightweight but less durable. Suitable for decorative shields.
• Thickness considerations: Aim for a thickness between 1/2 inch to 3/4 inch. The final thickness is up to you but consider what type of weight you are comfortable with.
• Metal Boss: A central metal dome, usually steel, used for hand protection and reinforcement. (Check out historical replica sellers for appropriate bosses)
• Grip Material: Leather or wood for the shield’s handle.
• Reinforcement Materials: Metal strips, leather, or rope. (Optional)
• Facing Material: Leather, rawhide, canvas, or linen. (Optional)
• Adhesive: High-quality wood glue for joining wood parts. Consider a suitable glue for any facing materials you may add as well.
• Fasteners: Wood screws, bolts, and/or rivets for attaching the boss and reinforcement materials.
• Finishing Materials: Varnish, paint, stain, linseed oil, etc., to protect and decorate the shield.
• Optional Decoration: Paint, leather dyes, or other materials for personalizing your shield.

Tools:

• Measuring Tools: Ruler, tape measure, compass, and square.
• Cutting Tools: Saw (jigsaw, circular saw, or hand saw), and scissors or utility knife for materials like leather or canvas.
• Shaping Tools: Plane, rasp, file, and/or sanding tools.
• Drilling Tools: Drill and drill bits.
• Fastening Tools: Screwdriver, wrench, and riveting tools.
• Clamps: For holding wood while gluing.
• Safety Equipment: Safety glasses, work gloves, and a dust mask.
• Marking Tools: Pen, pencil, and/or a marker for marking shapes on wood

Step-by-Step Guide to Making Your Wooden Shield

Now that you have all your materials and tools, let’s get to work! This guide will walk you through a general approach to building a round shield (similar to a Viking shield), but the principles can be applied to other shield shapes as well. Adapt as necessary.

Step 1: Designing Your Shield

Before making any cuts you need to plan out your shield to ensure you have the best possible outcome. Here’s how to plan your shield:

1. Decide on the size: Consider the size and shape of your shield. Draw out the final design on paper and note the dimensions. For a round shield, common diameters range from 20 to 36 inches.
2. Consider the thickness: Thicker shields will be heavier but more durable. A good starting point is 1/2 to 3/4 of an inch.
3. Plan the boss location: The boss will be placed in the center of the shield and will have a diameter of around 4-7 inches in diameter depending on the specific boss you have chosen. Ensure that you have enough room for hand movement behind the boss when you mount the grip.
4. Draw a template: Draw out the size of your shield using a pencil on some paper or cardboard. You may want to draw half the shield and fold the paper in half to cut out a symmetrical template. After this you can trace this shape onto your wood.

Step 2: Cutting the Shield Board

With your plan completed it is now time to prepare your wooden base:

1. Transfer the design: Place the template onto your wood and trace around it to mark the shape.
2. Cut the wood: Use your saw to carefully cut out the shape of the shield from the wooden board. If you use a jigsaw ensure that you go slowly and do not push the saw. Let the blade cut the wood by itself. Try to cut as close to your template line as possible.
3. Shape the edges: If needed use a rasp or plane to round off the edges of the shield. This makes it more comfortable and safer to handle. You can use a file or sandpaper for any fine tuning.

Step 3: Creating the Grip

The grip is one of the most important parts of the shield because it is the mechanism you will use to hold and move your shield. Here’s how to create your grip:

1. Choose your grip type: You can use a simple leather strap, a wooden handle, or even a metal handle.
2. Wooden Grip: If you opt for a wooden handle, cut two or more pieces of wood to the desired length and shape. You can round the edges for added comfort.
3. Attach the grip: Position the grip on the back of the shield, ensuring it is centered and comfortable to hold. Use screws or rivets to attach the grip securely. If you’re using a leather grip, punch holes and secure it with rivets or screws. You could also use glue and then rivet or screw it in for added security.
4. Adjust as needed: Make any adjustments to the placement to ensure it is comfortable to handle

Step 4: Installing the Boss

The boss is a crucial element for protecting the hand and adding strength to the center of the shield. Be very careful when installing this.

1. Mark the center: Find the exact center of your shield board using a ruler and pencil. You can use a straight edge connecting the edges of the shield on several points to easily find the center.
2. Drill pilot holes: Place your boss onto the center point you marked and make marks on the board where the screws will go. Using your drill and appropriately sized drill bit drill the pilot holes, this is important to avoid splitting the wood.
3. Mount the boss: Align the boss over the pilot holes and securely attach it with screws, bolts, or rivets. Ensure they are firmly in place to prevent the boss from falling off during use.

Step 5: Adding Reinforcement (Optional)

Reinforcement can significantly increase the longevity of the shield. Consider the following:

1. Choose reinforcement materials: You can use metal strips, leather bands, or even rope.
2. Position reinforcement: Place the reinforcement around the edges or across the face of the shield as desired. If you are adding metal along the edges it will also double as decoration.
3. Attach reinforcement: Secure the reinforcement using screws, rivets, or glue. Ensure that the materials are flush with the surface of the shield so you can attach facing later if you choose.

Step 6: Adding Facing (Optional)

A facing material like leather, rawhide, canvas, or linen can enhance the shield’s durability and appearance. Consider this step:

1. Prepare the facing material: Cut the facing material slightly larger than the shield board, this gives you room to trim the material after attaching it to the wood.
2. Apply adhesive: Apply a suitable adhesive to both the shield board and the facing material. Use a brush or a roller to spread it evenly. Be sure to follow the instructions on the type of glue you choose. Some adhesives will require you to wait before attaching the two parts.
3. Attach the facing: Carefully lay the facing material onto the shield, ensuring it is aligned properly. You can apply gentle pressure using a roller to ensure good contact with the adhesive.
4. Trim the edges: Once the adhesive has dried, use a sharp utility knife or scissors to trim the excess facing material from around the edges. Be careful and use a ruler or straight edge for best results.

Step 7: Finishing Your Shield

Finishing your shield is important for protection and can be used to create a unique look:

1. Sanding: If necessary, lightly sand the entire shield to remove any rough spots and prepare for finishing.
2. Applying a protective coating: Apply varnish, paint, stain, or linseed oil to protect the wood from moisture and wear. Allow this to dry completely. You can do several coats, sanding lightly in between each layer.
3. Decoration: Use paint, dyes, or other materials to personalize your shield. You can paint emblems, patterns, or your own designs to make it unique. Let it dry completely

Tips for Success

• Take your time: Rushing the process can lead to mistakes. Work carefully and methodically.
• Use quality materials: Invest in good wood and adhesive to ensure your shield is strong and durable.
• Test it out: Before using your shield in any serious activity, do some light testing to make sure everything is secure.
• Safety first: Always wear safety glasses and gloves when using power tools. Make sure that your working area is well lit and clear from clutter.
• Research: Look into historical shield construction for inspiration and guidance. There is a plethora of information available online and in libraries for historical examples.
• Don’t be afraid to experiment: There is no one right way to make a shield, so don’t be afraid to try different techniques and materials. Every shield is different and unique to the creator.

Conclusion

Building a wooden shield is a challenging but incredibly rewarding project. It combines woodworking skills, historical understanding, and creativity. With careful planning, quality materials, and attention to detail, you can create a beautiful and functional shield that you can be proud of. Whether you are a reenactor, cosplayer, or simply an enthusiast, your new wooden shield will be a unique and cherished item.

So, gather your tools, choose your materials, and embark on your shield-making adventure! Remember to research and prepare your project as thoroughly as possible to help ensure a great final product. Good luck and happy crafting!