Hoplite Shield

Here is a hoplite shield (called an aspis). Made from an oversized cork drink coaster.




Step 1: Get the cork drink coaster. Regular ones are around 9-10cm in diameter. You need one that is 14-15cm. I found mine on aliexpress.com

Step 2. Find two bowls - one larger than the other. Soak the coaster in water and press it between the two bowls. Put a weight on the small bowl to maintain pressure. Leave it like this overnight until it dries. It should retain its shape when you take it out.

Step 3: Shape the rim. I used my Dremel with a sanding drum.




Step 4: Paint. Cork is very absorbent so use a sealer first. Paint the main colour first and then do the rim.

Step 5: The armband. A strip of steel from a tuna can and a piece of bamboo.




Step 6: Cut out a liner and glue in place. This one is made from black leather.

Step 7: Cut and file the steel and bamboo to shape. Drill riveting holes in the steel. The rivets are tiny brass nails that I cut to length.

Step 8: Add eyelets around the perimeter for the carrying cord and hand grip. The carrying cord is a length of string and the hand grip is a twisted length of wire. You may need to glue everything in place as the nails and eyelets have trouble fixing in the soft cork

Finished

That. Is. Brilliant. A cork coaster!! Really cool idea. Ingenious. Thanks for posting this.

Nicely done and a fine tutorial.

Wow, amazing! love how you did the details on the back!

You are quite the shieldmaster, great work!