Clyde's Shield Box Mk1

This is a pattern for a shield box that I designed and use on shields designed for SCA armored combat. Made correctly, this is suitable for the normal stresses found in that activity.

Materials:

• Leather, vegetable-tanned, 14oz or better. 16oz recommended.
•  Approximately 1 1/2 sq foot.
• Seams.
• Riveted.
• 28 rivets of your preference. Rapid rivets are suitable.
• 10 1/2 in. of 1 to 1 1/8 in. wide strap leather ~8oz.
• Stitched.
• Good waxed linen type thread or artificial sinew. 
• I like 1.0mm Ritza Tiger Thread.
• 2 Leather stitching needles.
• Dowel rod, 1 1/4 in. dia., 5 1/4 - 5 3/8 in. long.
• Hardware.
• 1 - 6 in. x 1/4 bolt.
• 4 - 1/4 in. fender washers.
• 4 - 1/4 in. lock nuts.
• 3 - 1/4 in. carraige bolts. 
• Length appropriate for your application (thickness of shield + thickness of leather).
• 3 - 1/4 in. flat washers.
• Wax for hardening.
• Dye for leather - optional.
• Paint or sealer for dowel.

Tools:

• Drill with 17/64 or 9/32 drill bit.
• 1/2 in. socket or wrench.
• Knife to cut leather.
• Hole punch for bolt holes (1/4 in) and/or rivet holes.

Creating the box:

1. Layout the pattern and cut out the leather.
2. Cut 1/4 in. holes for bolts.If edge beveling, recommend beveling the long side and possible the tops of the bolt tabs. The bottom edges and the seams to be closed do not need to be beveled.
3. If you have a grooving tool, score a groove on the back side of the leather across the base of each bolt tab to make it easier to bend. 
4. Seams.
• Rivets.
• Cut rivet holes if necessary.
• Cut backer strips for rivets and cut holes.
• Stitching.
• Cut stitching holes about 3/16 to 1/4 in. edge of area to sew.
5. Optional - Apply leather dye. Let dry and buff to remove residue.
6. Stitch or rivet the two seams to form the box.
• I use a baseball style of stitch to pull the edges tight.
7. Using hot tap water, soak the entire piece until no bubbles are present.
8. Form the wet box to the desired shape and let dry.
9. Once dry, wax the box to further harden and seal it.

Prepare your handle:

1. Using a drill, drill a hole through the center of the dowel.
2. Seal the dowel with paint or a urethane sealer. Your preference.
3. Let dry.

Assembly:

1. Put one fender washer on the 6" bolt.
2. Start the bolt through 1 side of the box.
3. Add another fender washer, then the handle, then another fender washer.
4. Push the bolt thought the other side of the leather box and add the last fender washer.
5. Thread on a lock nut and tighten.

The box is now ready to be mounted to a shield.

Clydes Shield Box Pattern, folded in half.

Clydes Shield Box Pattern, complete with ruller for reference.

Shield box in form, drying to shape.

Shield with handle, separate.

Inside of shield box with handle mounted.

Shield box after wax has been applied.

Completed shield box and strapping.