Using a ghetto compas (2 paint sticks duct taped together) I made the general circle for the shield on a template on printer paper.
I decided the outside rim was too thick, so I made it thinner, I also don't like seeing my mistakes, so I covered over my lines in white paint. :P
I drew where I wanted the planks to be as well as for the metal part in the middle and the circle.
Created arm straps out of 4mm foam(ish).
Used 6-8mm foam (I forget which, but its the puzzle mats you can buy at costco) and traced my template around, and transfered the wood plank marks. Using a shield on amazon, I copied the wood grain patterns with a sharpie. To get the wood plank look I made v cuts into the foam with my exacto knife, so I could just peel a strip out of the foam without it going through all the way.
I needed to cut 2 pieces for the shield in order for it to be the thickness I wanted. In order for adhesive to stick, I dremeled around the inside edges of both pieces so that the contact cement would have more surface area to stick to.
I used a soldering iron to burn in the wood grain effects.
I cut out the trim for both the outside and inside edges. The outside edge had to be 4 seperate pieces glued together, because I didn't have any foam long enough. The half dome styrafoam ball is just a placeholder for now.
I used one end of a chicago screw to make the bolt looks in the trim. I just dremeled in holes on where I wanted them to go, filled the holes with super glue, then stuck the chicago screw in to make sure it wouldn't go anywhere.
To make the half dome ball for the center of the shield, I cut out a piece of thick foam, heated it with a heat gun, then smashed it into a bowl of the appropriate size.
The straps in the back are held together with chicaco screws. I put the non screwable side underneath, and the flathead side above so it can be re-adjusted if needed.
I used a lot of contact cement to smash the two pieces of foam together, dremeled out the edges so it would be smoother, and filled in any cracks with caulk. The guy who commissioned it from me wants a friend of his to paint it, so it will be going to him as is.