Adam Savage's One Day Builds: Upgrading Captain America Shield!

hey adam savage here in my cave with  a this isn't exactly a one-day build   it's more of a quick and dirty technique  but one that served me incredibly well   you recognize this is captain america's stealth  shield uh and if you're wondering if he has more   than one shield the answer is no there's only  one vibranium shield apparently they repaint it   per mission i didn't know that but when  i went to look up caps shield information   that's a fact this was made for me for my costume  by shield works you can find him on facebook   um beautiful work his paint job is magnificent  i've actually seen one of the real cap shields   in dan lanigan's collection and i will  tell you that shield works bullet hits are   exactly right it's a great bit of kit and i love  it and when it arrived it was missing one little   detail which is this border around the edge for  me that border is really critical and it wasn't   on the shield burst shield when it came and i  wanted to put it on but i was confronted with   this problem of this is a 24 inch ring that's  about three quarters of an inch wide how am i   going to cut that am i going to cut it with a  jigsaw oh that's a lot of sanding and no matter   how well you file it none of us are click spring  we can't get that good um am i going to send it   out to my friend kevin for water cutting i guess  i could but that's not going to happen in a day   and i don't want to make my problem his problem  and then i remembered a technique for cutting out   aluminum shapes that fond davis used on his first  battlebots robot mouser mecha catbot meow meow   it's actually required to say meow meow every  time you say melser mega catbot anyway fawn cut   out the main half inch thick aluminum frame  of mouse or catbot using a normal router i helped him do it and yet i've never used a  router and a template to cut large chunks of   aluminum out so i decided to on this and i'm going  to walk you through the process because it was   easy peasy now sometimes people ship me stuff in  foam board and i save all the foam board so this   is a piece of scrap half inch foam core board  that was part of a thing that got mailed to me   and this is my perfect flat  base for this operation this this is my piece of aluminum um i think i cut the  real one no i cut it out of just about this stuff   this is like 80 thou so i'm going to lightly glue  this piece of aluminum down onto the foam board   i'm going to use pro stick  high strength spray adhesive   i really like this stuff it's  very it's tenacious so here we go now this stuff is nice and tenacious but you got  to glue it at the right time you can't just stick   the aluminum down immediately you got to let it  flash off a little bit get a little bit tacky   yeah still still a little too  wet it happens quickly but you need the stick actually i'm just  going to make sure i'm fully covered here okay all right i like that  tack here we go i'm just going   to lay this piece of aluminum  down on here yeah there we go i'm just going to start with  the center on the diagonal one of the complications is is that all my stock  in this shop is 24 by 48 inches that's the largest   size i store and this ring is exactly 24 inches  in diameter so uh i don't have a lot of margin of error and an eighth inch bit all right milwaukee were sponsors  of my discovery show savage builds   and one of the bits of the kit was this router uh look at the number on this this is a dialysis this  is their uh 5615-20 router and i have to say this   is a really nice bit of kit this router it is  a workhorse it is beefy and powerful and simple   i really dig all that about it and this is going  to be our main tool for cutting out the aluminum   all right now i'm going to want to use a  short shank there we go this is the one   yeah so you could go with a quarter inch  shank or a half inch shank because i'm cutting   metal and i don't want the cut to get too hot i'm  going to use a half inch shank and a half inch   uh acts as a kind of a heat heat  sink uh pulls heat away from the cut   this is a bit i used the first time i did this  in preparation for this video and i screwed it   up because i let it get too hot and it shattered  the carbide edges of the blade yeah it's the   cost of being impatient so i'm going to use  a nicer bit uh and this one is 3 8. okay best practice with a router always leave  it unplugged when you're working on it i've told you that i'm terrified of  table saws i'm way more terrified of routers now now it's time for a little bit of math  because what i want is i want to cut out   the inside and the outside of a ring which means  i have to account for the 3 8 of an inch of the   width of this bit on the radius that i'm going  to be cutting so uh that's easy to figure out   for the first part which is that the radius is  going to be exactly 12 inches from right here   to the edge of that blade i'm going to set my  calipers to zero bring them out to 12 inches yep all right so exactly 12 inches from that  line to the inside of that bit that'll give me   a 24 inch diameter ring and if i pivot it in the  center here it should all work out pretty nicely now before i plug it in  let's just check my extents damn brother yep it's pretty tight so we're  about to make a crap ton of noise ah here we go this is noisy and it's messy however i must say i've been  really impressed with how   fast this technique works so  we're gonna turn it on there we go turning making sure i have the  room to move all the way around   okay here we go i think i  start here yeah here we go a note to be careful when you are exiting and  entering and exiting the material you saw that   as it uh came free of the sheet it wanted to  run because i'm cutting in the direction uh but   come take a look at this edge that is beautiful  that's that's a machine edge right there   at at this point when i was making  that ring before c2e2 i was a very   happy camper now it's time to make the second  cut now it's about the thickness of the ring   and on this i went with what i thought  was aesthetically correct about 0.875 oh that's the thickness of my ring right there  so now i need a new measurement which is the   measurement the depth measurement  between these two yeah there we go   so right there the amount of extra space  there that's simply the width of my ring   added to the width of the bit because now  i'm measuring to the outside of the bit yeah there we go that seems  darn close enough so then now we're going to the outside oh now we're going to the outside and oh look at that if it's neatly right through  that hole right in the middle there that's awesome okay it's important to note the order of  operations i cut the outside of the ring   first because i want the glue of the entire piece  holding it in position if i cut the inside first   then i'm only holding on to what i'm cutting  with this outside you want as much surface   area as possible to bring to bear on holding your  work down the other thing that i really love about   this is the use of the foam core it's super flat  but it totally does not interrupt my bits at all   it's really really friendly to them and i dig that  i dig that about you jerry all right there we go perfect all right here we go plugging in my other router still works but its  switch is broken in the on position   which it makes it a router for those  who like action but not for most people   all right here we go let's start  here we're going to move around with and there we have it look i'm as impressed as  you are i really dig this technique because   many of the ways to do and get a  ring of this precision and this size   involved big expensive pieces of machinery  and that was literally 20 minutes start to   finish you know and i stopped to talk to you  for a while so it's like it's a very very fast   technique and what it yields is amazing  all right so let's get this puppy up here a little bit of a solvent like bastine or acetone  will clear up the glue that's sitting on there   to be honest i'm going to leave this piece  of aluminum attached here because i could   use it as a i could use it as my baseboard for any  other template like if i wanted to make a certain   smaller ring and i wanted to make it template  to run it through this is it's already mounted   and look at this this is that is without any  finishing that's not even an overly sharp edge   ah that i gotta say like i knew about this  technique intellectually no i'm in love with it   emotionally and then when it was time to  attach it to this i simply used epoxy glue   um i've talked about glues before uh for a wide  flat surface you want a bit of tooth so i actually   hit this with like 80 grit sandpaper all the way  around really made it rough on one side then i   applied some 10-minute epoxy all the way around  the ring turned it over and laid it down and then   as a clamping mechanism i used a whole crap ton  of clothes pins just to hold it down normally i   don't like the idea of using epoxy and  aluminum for a structural hold because   aluminum moves a lot it's flexible it's  lightweight like things will work themselves   away however with a wide expanse like this on the  brake on the brace of a bowl of aluminum i had no   problem with that at all i think that uh heaven or  hell won't rent us under these two now that i've   clamped them together and that was a half hour  solution to what felt like a full day problem hey everyone adam savage here in my cave  and we are living through a completely   strange moment in time six months ago the  entire world changed everyone went into lockdown   and so did tested we became a virtual workplace  almost overnight and now i see all my colleagues   almost exclusively on video chat i am shooting  only on the phone i know the sound quality's   gotten worse norm joey and gunther are all  editing from home and maybe the biggest   change is output we have radically increased  the number of videos that we make because   well that's what i'm doing all week long  here is just shooting everything on my phone   and eventually the world will return to  normal but one of the things we want to keep   up is the pace of videos that we've been releasing  we've been ecstatic about your feedback about this   and we want to keep it going but in order to we  need to ask for your direct support and so i'm   here today to announce tested channel membership  if you're not interested in becoming a member   that's fine tested is not going to change for you  you still get all the same great one-day builds   tool tips the podcast etc but if you are willing  to join we've got some pretty cool extras and two   levels at which to join for a buck 99 a month we  have our supporter level and for 9.99 a month our   patron level which includes all the stuff from the  supporter level and some live streams some direct   access to me and the tested team and some sneak  peeks into our entire tested workflow and process   we are so excited about the new possibilities  that channel membership opens up and we know   that many of you have been supporting us all along  as tested premium members and to you i say thank   you your support has meant everything and you  can keep it going by hitting our brand new join   button somewhere on this screen thank you guys for  watching and between you and me i am most excited   by the live streams i really love doing those  earlier this summer and i can't wait to pick it up again

Channel: Adam Savage’s Tested

Views: 1,297,059

Keywords: tested, testedcom, one day builds, tested adam savage one day build, tested one day builds, adam savage one day build, adam savages one day builds, one day builds adam savage, adam savage, cosplay, captain america, costume, shield, avengers, adam savage cosplay, adam savage tested, marvel, captain america cosplay, captain america cosplay costume, captain america cosplay shield, adam savage costume, adam savage builds, adam one day build, tested adam savage, one day build

Id: OxkszitNWN8

Length: 17min 45sec (1065 seconds)

Published: Wed Sep 02 2020