Well, here it is: make your own shield in five easy steps.*
*Disclaimer: This is not actual a how-to guide, merely an overview of the steps used in the system I was taught. If there's interest, I'll make an instructional video and walk through the steps while making a demo shield.
Tools: While this could conceivably be done with hand tools, it would be very labor and time intensive. We took advantage of several tools to help with the process: drill press, band saw, chop saw, belt sander, orbital sander.
There are other things you can do based on your preference like staining, burning, scarring, painting, etc. I left that out because it's window dressing to the fabrication.
Originally posted: Monday, February 10, 2014.
Edited for repost: Sunday, September 18, 2016.