How To Make A Sword

Materials:
1-4' PVC pipe-3/4"
1-roll 72"x40" closed-cell foam-1/2" thick
1-4' dowel rod
1-roll of duct tape
1-hot glue gun
Lots of hot glue sticks-white not clear

Instructions:
*This will make a sword that has a 3 foot blade and a 1 foot handle.  It will be a two-handed sword.  If you choose to make a smaller, one-handed sword, then make the blade 32".

1.)  Cut the dowle rod and the PVC pipe to desired length.

2.) Wrap the dowel rod (3/4") with duct tape.  Make sure you cover it vertically not horizontally.  Make each piece of duct tape long enough to go from one tip to the other.  Try not to fold, crease or bubble the duct tape.

3.)  Now, slide the covered dowel rod into the end of the 3/4" PVC pipe.  If you messed up the taping of the dowel rod, then now you will feel stupid.

4.)  Cut 4 strips of the foam at 1 1/2".  Glue 2 of them together to get 1 inch of foam.  You should have 2 sets of foam strips.

5.)  Glue one set to the side of the PVC pipe with the hot glue.  Then, glue the other set to the other side of the pipe with hot glue, also.  The foam should be directly across from one another.  Do your best.  There is no perfection in this.

* I cut the foam to 3 foot, from the tip to the top of the hilt.  Some people will cover the handle in foam also.  I didn't like it, but you can do whatever you want to.

6.)  Next, cut 2 strips of the 1/2" foam, so that it will fit in between the two foam edges.  And glue it down.

7.)  After everything has dried, rip strips of duct tape long enough to fit around the blade.  Use about 6-8 strips.  You do not have to cover the entire blade, unless you want to.  Tape the blade with the duct tape.  DO NOT COMPRESS THE FOAM!  LET THE FOAM STAY AS IT IS AND DO NOT MAKE THE DUCT TAPE VERY TIGHT.

8.)  For the hilt, you can use anything.  I took to 8 inch pieces of foam-width of 3 inches-and folded them in half.  Then I duct taped them to themselves.  Then glue them to the PVC pipe right under the end of the blade.

9.)  Next, I wrapped the handle in duct tape.  Then I took cloth tape and wrapped it to give the sword better grip.  Whether you put foam on the handle or not, wrap it in duct tape and cloth tape.

10.)  Finally, take a piece of cloth that has been sewn to fit the sword.  The cloth should go from the tip to over the hilt.  Tie a piece of string on top of the hilt and below it.

NOW YOU HAVE A SWORD!

YOUR FIRST ONE WILL SUCK!

TOUGH!

YOUR SECOND ONE WILL BE MUCH BETTER.  TRUST ME!

ENJOY!!!!!!!!!!!!!!!!!!!!!!!!!