Used the ("Wrist to elbow"*2)+5" formula for the diameter. 1"x1/8" metal strapping and wood screws to hold it all together. Screws protrude through to the front and I bent them over with a hammer. They used to use nails that they would bend over on the front. I figured screws would hold the wood a bit better, even if a tad weaker in cross-section. Used a 1"x4" to add a center support and hand grip. Center cut a hole for knuckle clearance.
Now I'm fabricating the boss. Picked up some 16ga cold rolled from Menards. Cut a 8" and 10" circle from the sheet with hand shears.
Then I realized, I had no idea how to dish it out into the rounded dome with a flange. Google to the rescue...
http://www.arador.com/construction/shieldboss.html
Which led me to...
http://www.arador.com/articles/stump.html
Ok... Sounds simple enough. Went out to the wood pile and found a chunk of Ash about the right size. Used a regular hammer and a wood chisel to rough out a 5"x1" dish shape in the top of the stump. Grabbed my 3lbs hammer and went to work. After finagling things around a bit, I got the technique down and was able to shape out a flanged boss for my sons shield. I'll work on mine later and see if I can't snap some photos to add to this post... And yes, this was a lot noisier than I thought it would be. Ear plugs and a glove on your off hand are highly recommended.
Left to do are to face the shields with canvas and glue. Paint a fearsome design. Mount the boss. Last step is to edge the rim with leather. Looking kind of crude so far, but this is a "first effort" so later results might turn out better.
And yes, all of the above should give everyone an idea of exactly how much of a Novice I am at all of this... ;-)
ETA: Crappy iPhone pics.


