***More pictures and patterns are on the way***


What you will need to make a Ninth Legion scutum.
	-3 pieces of 1/8 inch luan plywood (door skins)
	-About a gallon of wood glue 
	-About 2 yards of 60" fabric (a thin canvas is best)
	-20' of 3/8"rope. (I like manila, but nylon works to)  
	-6' of black rubber hose.
	-a gallon of primer (optional unless you use a printed fabric)
	-half gallon of red paint 
	-a quart of yellow 
	-a couple of gold paint pens (optional but the finish looks good)
	-a couple of black shapie markers 
	-a steel shield boss with 10 bolts  
Tools you will need
	-a drill with 1", 1/4", and a 1/8" drill bits.
	-a Jig saw 
	-a ratchet set or at least a couple of crescent wrenches.
	-a knife of some kind (to cut leather and fabric)
	-a set of paint brushes (a large on to spread the glue and different sizes to
 	 do the detailed drawings)
	-at least 24 spring clamps (the more the better)
	-a shield press. (you might need to make one of these.
The Steps
	Cut your wood.
		Cut the wood to size. 
		Drill a hole in the center to fit the blanks on the press.
		  Offset the hole or down an inch so you can cut a carry
 		  handle in the shield boss.
		 
	Assembly 
		Place the bottom piece of wood on the press.
		Apply a good layer of glue all over the first layer 
		Place the middle layer on top of the bottom layer 
		  some glue might squeeze out, thats ok. 
		Apply a good layer of glue to middle layer.
		Place the top layer on last.
		Put the top of the press on and tighten to get the correct
 		 curve. (about 6 inches of curve) 
		Clamp down the edges with the spring clamps 
		  one about every 6 to 8 inches

	Wait at least 12 hours to dry. (waiting a day is best)

	Cut the shield to size. 
		Mark your final height and width with a pencil.
		Don' t forget to round the corners a little bit.
		Use your jig saw to cut the final shape. 

	Congratulations you now have a shield blank!

	Covering your shield blank.
		Spread and even coat of glue on the back of your shield.
		Take your fabric and cut a slightly larger then needed piece
  		 for the back.
		Glue the fabric to the back of your shield.
		Wait 2 hours to dry. 
		Cut the excess fabric from around the sheild
		Take your rope and cut a piece that will go around the
 		 circumference of the shield (the rope will help protect the
 		 shield edge form abuse).
		Cut a piece of fabric for the front that is about 12 inches
 		 longer in each direction.
		Glue the front piece to the front of the shield leaving about
		 6 inches of overlap on all the sides.
		Once the glue sets on the front, place the rope around the
 		 shield and glue down the overlap to the back of the shield.   
		Wait for it to dry.

	Cut the center boss hole.
		To leave a carry handle. Mark out and cut 2 D shaped holes
 		 the size of the boss in the shield (pictures coming soon)

	Paint your shield.

		Full view of our shield
		Detailed view

		Primer the front and back (gray is the best color for this)
		Paint the front red. 
		After the base coats are dry you are ready to start the design
 		 work. 
		USE A PENCIL for the out lines, its easy to mess up.
		Mark the out line of the boss in the center of the shield.
		Use the wings, trident, lightning bolt and placard patterns
  		 to outline your designs on the shield. Don't draw in the
 		 detail yet.
		Once you have everything outlined paint the outlines in
 		 yellow. (It might take a couple of coats yellow)   
		Now when the yellow is done take a sharpie and carefully
 		 outline all the elements on the shield.
		Take the wing patterns and use the dot system to outline the
 		 details (the feathers). Use a pencil to first connect the dots
 		 and draw in the feathers. 
		Use the gold paint pens to paint alternating feather for a
 		 great finish (see picture for a good example).
		Finally go over the outline of the feathers with the shapie.

	Mounting your shield boss
		First paint your shield boss with brass or bronze spray paint.
		Center your boss over the hole you cut in shield earlier (this
 		 should be about the center of your shield. 
		Mark your holes and drill.
		Bolt on your boss.

	Strapping your shield.
		You will need:
			A 3" by 12" strip of leather (good thick stuff).
			A handle of some kind (some people just use
 			 another thiner strip of leather or maybe a
 			 garage door handle, it should be comfortable
 			 for your to grip and strong)
			Some nuts, bolts and big washers.
		
		Back of the shield
	
		You might need help with this one. 
		Put your shield arm armor on (elbow cop, vambrace and
 		 glove).
		Hold your arm with your upper arm straight down at your
 		 side and your elbow bent at about  a 45 degree angle.
		Have some one hold the shield up so that just your eyes
 		 peek over the top.
		Mark where your arm is on the shield.
		Cut  the leather strap so it fits easily around your forearm
 		 armor just before your elbow. (give yourself an extra inch
 		 or 2 so you can get your arm out of the shield easily.
		Bolt the two ends to the shield where you marked earlier.
 		 (don't forget the washers for the leather)
		Bolt your handle to where you marked your hand.

You are ready to fight with your new shield.    			

Write up by Gnaeus Aquilius Longus 10/16/2002