LEVEL 1 SWORD
This is a simple sword for moderate combat use.
The process is covered here but for information on the specific supplies and techniques click here
   

CLICK HERE FOR THE VIDEO

 

Supplies:
1/2" PVC (30 inch length)
28" of a hollow core swim noodle
Duct tape and Hockey tape
Spray Adhesive, Silicone caulk, retractable razor utility knife, sandpaper, and a saw for cutting PVC.

 

Step 1:
Cut the 1/2" PVC pipe to a 30" length. Sand each end to remove and sharp or rough edges. Sand the length of the pipe (this really helps increase the strength of the adhesives) and wipe it off with a clean cloth.

 

Step 2:
Cap off each end of the PVC. Place a penny on each end and cover it with duct tape as shown.

 

Making each end neat gives the capping good strength and helps a lot when you push the ends through the tight fitting opening of the swim noodle.

  See how pretty! Do this on each side.
  Step 3:
Cut the swim noodle to a length of 28" with your retractable knife. If you extend the blade fully, it is an easy cut.
  Step 4:
Using the silicone caulk, cover the top 12" of the PVC with a moderate amount.
  Step 5:
Now carefully slide the PVC (by twisting and pushing) through the center of the swim noodle until the PVC is an inch and a half from the opening.
 

Step 6:
Cut about 3" off the bottom portion and slide it down until it is over the edge of the PVC by about an inch.

  Each end (the blade and the pommel) should look similar to this.
  Step 7:
Cut another inch or so off the bottom of the blade and make a vertical cut to remove it from the handle.
  Step 8:
Cut a slice (about an 1/8) of the piece you've just removed. This will be a plug for the blade tip.
  Step 9:
Put a moderate amount of silicone caulk in the opening and pop the plug in. Do the same for the pommel side.
  It is better to have the plug be too long then too short. If it extends you can trim the excess with your knife.
 

Step 10:
It is vital that the "poking" end is safe so I like to glue a scrap piece of closed-cell foam to each end with spray adhesive. You could also cut a 3" piece from your leftover foam and cut it in half lengthwise (so you have a 3" half cylinder). Glue this to each end and trip the excess.

If you choose not to add a safety tip, cover the end with duct tape to add additional support for the foam plug.

  Step 11:
Using a 1" thick piece of scrap open-celled foam, cover each end. Spray adhesive works great for this. Trim the excess.
 

Step 12:
Put two pieces of duct tape over the blade end - one perpendicular to the other so they crisscross over the end. Don't pull too tightly - you don't want to crush the open-celled foam. It needs to stay "cushee."

Then wrap the duct tape around the circumference of the blade. Do the same with the pommel end.

  Step 13:
Use the hockey tape to cover the duct tape. Duct tape is not fun to get hit with and the hockey tape provides a nice finished look.
  Step 14:
If the tip of the blade is not snapping back it means that air is not escaping. Use a sharp X-acto blade to puncture holes along the edges to let the air escape and the foam snap back.
  Step 15:
Start the handle taping using duct tape as shown.
  Step 16:
Use these photos for suggestions to lay in the hockey tape.
  Step 17:
Finish by wrapping the pommel...
  then the handle.
  That's it! Now make one for a friend and it's off to battle!