How to Make a Cardboard Knight's Shield

Many children go through periods of wanting to play knights and sword-fighting. Knights are a perennial Halloween costume choice, too. While you can find plastic shields in toy stores, they won't be fitted to just the right size for your child, and they can't be customized with the right colors and designs on the front to match your homemade costume. Corrugated cardboard is a versatile construction material for making play shields that will delight every would-be hero in your family.

Difficulty: Moderate

Instructions

Things You'll Need:

• 2 pieces of large corrugated cardboard
• Ruler
• Pencil or marker
• Box cutter or other sharp kitchen knife
• Serrated bread knife
• Scissors
• Duct tape
• White craft glue
• Acrylic paints and brushes

1. Measure the child's arm from fist to inside elbow, and plan a shield that is a little bit wider than this measurement. Choose the shape of the shield: oval, rectangle, circle or classic "shield" shape (flat on top and pointed at bottom).

2. Choose 2 pieces of sturdy cardboard. Sketch your shield shape on both pieces.

3. Cut the cardboard, using a box cutter or a long serrated bread knife. Try to maintain crisp edges. (A bread knife will give you the best results.)

4. 
    

   Hold 1 piece of cardboard to the child's arm. Mark where your child's fist is, and then mark the place just inside his elbow. These are the points where you will place arm straps.

5. 
    

   Cut a horizontal slit above and below each mark. Each slit should be large enough to thread duct tape through it, and they should be 4 to 6 inches apart, depending on the size of the arm.

6. Measure pieces of duct tape 10 or 12 inches long. Each strip should be long enough to go around the arm or hand, neither too loose nor too tight, and through the slits. Make sure it's long enough that you have a few inches to stick on the side of the inner shield.

7. 
    

   Thread duct tape through the slits, sticky side out, so that on the other side, the sticky side will face the cardboard. Stick it firmly on the inner side.

8. 
    

   Use shorter strips of duct tape to bind and cover the arm strap. Cover all sticky edges, and make it as thick or as thin as you want for the child's arm or hand to grasp.

9. 
    

   Cover the ends on the inner side with more duct tape, to reinforce the attachment.

10. Spread white craft glue evenly on the inner sides of both shield pieces, and put them together, pressing firmly. Allow the glue to dry.

11. Paint the front of the shield as desired. Reinforce the shield's edges with duct tape binding.

Tips & Warnings

• Shield will be stronger if the corrugated ridges run vertical on one piece and horizontal on the other.
• Glue a piece of poster board on the front for extra strength and a nice finished look. You can also cover the front with shelf liner that has adhesive backing.
• You can also use cloth arm straps, attaching them to the wrong side of the inner shield with duct tape. Cloth straps may be more comfortable for a small child's use.
• Remember that a cardboard play shield is costume gear, not real protection. Children must always be supervised when using play swords.

[dekotaarmstrong]

on 10/27/2008 By Lesa 10/27/08
my son is going to be happy with this thank you.

[grouch]

on 1/7/2008 My son is going to love this. Thanks for the great distraction project.