Here are some directions for making a simple buckler in the Georgian (country, not state) style. The main difference is that more Western bucklers have a solid grip in the center and the Georgian style has a leather strap that allows you a more adjustable grip.
Materials (for 1 buckler):
- ½” thick plywood
- 4x rings, metal (D or O)
- 4x split cotter pins
- 8x small metal washers
- 4 feet nylon webbing
- Yoga mat or other squishy material
- Duct or Gaffers Tape
Step 1: Cut the Buckler
I used a router jig that allows me to choose various sizes of circle. For these bucklers I chose to make them 12 inch diameter. I cut out several blanks.
Step 2: Make the Jig
Out of cardboard I cut a 12 inch diameter circle. I then punched four holes, each about 3” from the center, to make a square/rectangle. This allows me to quickly mark the holes for drilling later.
Step 3: Drill the Holes
Lay the jig on your cutout rounds & mark the location of the holes, then drill the four holes. Make sure the drill bit is just big enough for your pins to fit but not too big.
Step 4: Assemble the Pins
Slip one of the Rings into the eye of the split pin, then load a washer on the pin. Push the pin through the wood, add another washer, and then spread the split arms – either hammering them into the face or adding some staples. Pay attention so that all of your rings are on the same face! This will be the side you place the grip on.
Step 5: Assemble the Grip
Take your 4 feet of nylon webbing and weave it through the rings – starting in one corner of the rectangle move to the one directly in line, then across, then down to the opposite side of the first ring. Then even up the ends and stitch them together.
Step 6: Add the Padding
I just eyeballed and cut out some pieces from an old yoga mat and used some spray adhesive to attach it.
Step 7: Finishing Touches
At this point I gave the outside a coat of spray paint (yellow as it’s what I had), then sanded the edges to make them a bit more round before putting gaffers tape all around the rim.