Shields Cut Here are the ten brass shields cut, drilled, and sanded into the correct shape. The plastic template used to shape them is the one on the right.
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Rolling out the Shape To obtain the correct curvature, each shield was rolled into shape with a round bar. If this was not done, there would be constant tension on the shield when it was soldered. Giving it a curved shape before soldering ensured that the sides of the shields would remain vertical.
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A Soldering Jig
After cutting the ten lower shields, I had no interest in cutting the ten tops, so ten square pieces were cut to fit the shields, and I could trim them after they were soldered on.
To ensure they would all be identical, I made a jig to hold the top and bottoms together so they could be soldered.
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