Making a Wooden Shield

We made a wooden shield out of 3/4″ hardwood plywood.  To get the perimeter, we bent an aluminum bar into the shape of one side, and then used it to trace both sides, making it symmetrical.

We softened a section of 4″ PVC pipe and flattened one side.  After plenty of sanding the endges, we screwed it to the back of the shield with 3/4″ screws.

We cut the handle out of a section of 2×4 on the bandsaw, routed, and sanded it smooth.  Here are the pictures!  All done but a coat of gold or silver paint.

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