You see if you just wrap foam in duct tape then it will feel like you're being smacked every time you get hit. This step might seem like a lot of extra work but trust me, it's worth it. It makes the sword more solid and gives even more padding for stabbing. One last thing I always do is tightly stuff the blade end of the core slightly over the top with scrap pieces of foam, then use electrical tape to hold it all down. I know in the video and in some pictures you will see mine only half wrapped, but if you want the sword to last you must wrap the whole thing. Then wrap the ENTIRE foam blade in duct tape. Now that your blade is on the core you may notice that the pipe insulation has split in some places. This will be your padding for stabbing (and believe me, it's important). Also, make sure that you leave around 1/2" overhang on the end. I find that by alternating where I pull on the foam can help prevent stretching. Once the foam has been prepared then pull it onto the core (make sure the taped end goes first). Once you have it cut to length, then tape over the seam every couple of inches with electrical tape and make sure that your taping starts flush with one end of the foam (this is going to be the end that goes onto the pipe first). So for example if your core is 3' long then you would cut the foam to be 2-1/2' long. The length needs to be at least 1/2' (6 inches) shorter than your PVC core (the difference between the blade foam and the core is how much handle you get). First, take the pipe insulation and cut it to length. Go ahead and mark the end that you inserted the stopper through since that is the end that is going to be the handle. After I got the stopper made then I applied hot glue around the edges and quickly rammed it down the pipe to the nail. I found the easiest way to make it is to hot glue a dime onto a scrap piece of foam (like what's used for shadowing tool boxes) and cut it out with scissors (this way there will be extra foam around the dime). The method you use to make this can vary. Once you've done that then you need to make a stopper to go in the center of the pipe. ![]() If your nail goes through the entire pipe then make sure you cut it down and sand it flush with the pipe. Next, drill a very small hole in the center to accommodate a small nail. ![]() If you are using 3' of pipe then this will be 1-1/2' from one end. If you use something thicker the amount of padding required to make it safe will make the blade too bulky.Īll of that being said, the first thing you need to do is cut the PVC to the desired length (3' is what I use but you can do what you want, although I wouldn't go any longer than 3-1/2') and find the center of the pipe. The other reason you need to use thin walled is because it requires less foam padding. I chose to use thin walled PVC because although rigid, it is still quite flexible and this will prevent it from snapping or shattering (can you tell I've broken a lot of training swords?). The first thing you are going to need is the PVC core. Guard Template (download and print in normal sheet size).Double sided tape (if you wrap the handle in paracord).Paracord or leather strips (pretty much whatever you want to wrap the handle in).3/4" thin walled PVC pipe (needs to be cut to the overall length of your sword).If you can't find both then make one sleeve be durable and put another one on top of that for softness) Fabric for the blade sleeve (This fabric needs to be extremely durable and soft. ![]() Paint (you want it to look shiny don't ya?).7/8 drill bit (I used an Irwin Speed Bore).Belt Sander (or something to round the edges of the wooden guard).Rotary cutter (optional for cutting fabric).Ram rod (needs to fit semi loosely in PVC pipe).PVC pipe cutter (or a regular old saw). ![]() If you have any questions at all be sure and leave them in the comments and I will answer them as soon as possible. Also, there are two templates available, one for several guards and one for a single guard. The video has some awesome demo's at the beginning and end and a helpful build tutorial in between so make sure you check it out: Here. The foam padding and soft sleeve make for a blade that you can be hit by all day long without being bruised. They are weighted and balanced to replicate an actual sword. However, being able to swing a sword gracefully doesn't come without practice, and being able to efficiently win in battle doesn't come without constant dueling and building of your reaction skills, and that requires good training swords. I was obsessed, sword fighting was like no other sport I had ever played, and I desired to become one of the best in my class. I wasn't very good at first but after a few weeks I was beating my way through half the line. Several years ago I took a class in medieval style sword fighting.
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