A round shield is a versatile defensive tool that has been used by warriors throughout history. This guide shows how to build a lightweight, yet sturdy shield using common materials, ensuring you gain both practical skills and a sense of historical craftsmanship.

Materials Required

• ½‑inch plywood board (cut to a 2‑foot diameter circle)
• Two leather straps, at least 6 inches long, for handles
• Light metal shelving bars, roughly 4 feet long, for the rim
• Twelve plumber’s brackets for securing the rim
• Standard bicycle tire (slightly smaller than the shield diameter)
• One hubcap for the central boss

Step 1: Shape the Core

Trace a 2‑foot diameter circle on the plywood and cut it out. Mark two points on each side of the circle, just above and below the center, one inch from the edge. Glue a leather strap between each pair of points to create comfortable handles that will accommodate your arm.

Step 2: Reinforce the Edge

Bend the metal shelving bars to match the shield’s circumference. Clamp them over the outer edge and attach them with plumber’s brackets—use enough brackets to secure the rim firmly. Bolt the brackets into place.

Step 3: Shape the Surface

Wrap the bicycle tire around the shield’s rim. Because the tire’s diameter is slightly smaller, the tension will form a subtle dome shape. Use the handles to pull inward as needed. If the plywood has uneven spots, steam it gently to smooth the surface.

Step 4: Add the Boss and Finish

Screw the hubcap into the center of the shield to serve as the boss. Paint or etch the shield with a design of your choice. Optionally, remove the tire to expose the sharp edge for defensive or offensive use.

TL;DR

Cut side notches for spear or sword play, and consider drilling a spear hole through the boss for added versatility.

Safety Note

This is a lightweight shield. It does not protect against heavy weapons or bullets.