Here we are going to have a gallery tutorial on how to make swords!

Note: Even if you follow all of these instructions, there is a chance that the weapon you make may not meet safety regulations of the game that you are attending.  If you can bring a backup, or be prepared to have to borrow a weapon from the game, it is suggested.

Things you will need:

• PVC pipe, preferably 3/4s inch wide (Home Depot, Lowes, Similar Stores)
• Duct tape of multiple colors (Duck Tape is pretty good!)
• A box cutter
• A hack saw
• Open Cell Foam (Couch cushions)
• Foam Pipe Insulation 5/8ths inch wall thickness (Frost King is usual, 5/8ths is REQUIRED)

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  First, get your supplies together. This is open cell foam, which is called Couch Cushion in the real world.

  

  This is pipe insulation, or closed cell foam. You want 5/8ths inch wall thickness, which you will have to order special at your local Ace Hardware, or other such store.

  

  Get PVC pipe, preferably 3/4s inch wide. Any thicker and you can’t use it, any thinner and it is likely to snap. In addition you want: ~Ducttape of multiple colors ~A box cutter ~A hack saw

  

  Cut your PVC pipe to be at least six inches shorter than you want your sword.

  
  

  

  After sanding any barbs off of the pipe, tape off both ends so that nothing can get into the pipe.

  

  

  Now take out your insulation.

  

  Next you want to put a few pieces of reversed duct tape on your pipe. This will help stick the foam to the pipe. Some like to use spray adhesive, but I find it horrible to work with and less effective. Not only that, but if you want to reuse pipe later, taking off foam that had been sprayed on to the pipe is a pain in the butt. (Stay tuned for two ways to reverse duct tape in the near future! This is how I have done it in the past, but Jon Gehman has a much better method.)

  
  

  

  When you cut your foam, you want to cut it so that you can leave a good sized grip at the bottom. Remember to assume that your have to have enough room for your hand, some extra space, and at least 1 inch at the bottom for the rear thrusting tip. Note that the pipe foam extends past the end of the pipe. This is important.

  

  We cut a thin strip off of the pipe insulation all the way down so that it fit snugly around the pipe. Then we closed the gap with pieces of tape all along the blade. NONE of these pieces wrap all the way around the blade. NEVER wrap ANY ducttape all the way, horizontally, around the business end of your blade. It crushes the insulation and makes the blade dangerous.

  

  Note that the end of our foam comes past the end of our pipe.

  

  You should be able to get your finger up to the first knuckle into this gap. About 1/2 to 3/4 of an inch. Some prefer to go up to an inch. I suggest not going more than an inch, as it can cause the padding to become weak and break.

  
  

  

  Using couch foam, cut your self a thrusting tip. It should be at least two inches high. I make mine a little longer cause I want to hurt NO ONE.

  

  Take your time and make sure it matches the circumference of your blade.

  

  

  Taking pieces of foam left over from the thrusting tip, stuff the end of the pipe insulation.

  
  

  

  Like so. Some prefer to stuff this part with scraps of closed cell foam, which is the pipe insulation, because it is stronger.

  

  Then tape over it. This is an important step, as it stops the pipe from gradually sneaking up the insulation and eventually extending into the thrusting tip, which is dangerous.

  

  I like to angle the grip end of my blade like so, as it makes it easier for me to apply the ducttape to stick the blade to the pipe.

  

  This is not entirely necessary, but I have found that it makes the sword a little more durable and easy to work with.

  
  

  

  Then tape it to the pipe. Try to make all of your tape smooth.

  

  Using old insulation from a broken sword, we are going to make our guard. I have cut a hole in the middle so that I can slide the pipe through.

  

  Pretty. Then I stripped the old tape off of it and set it aside.

  

  Using a long, hopefully continuous piece of ducttape, I taped my thrusting tip onto the end of the sword. ALWAYS go with the blade. Never go around the blade.

  
  

  

  Repeat the process until your blade is covered. Try to avoid overlapping the ducttape as much as possible.

  

  Now I slid the guard back onto the pipe. This is a decorative piece to the sword, so here you can get creative. As long as it is not dangerous, you can have fun. Get inventive! (How to make basket hilts: coming soon!)

  

  

  I began to tape over my hilt guard with black tape, only extending onto the blade about 1/2 of an inch. See how pretty?

  
  

  

  Now, take a small piece of pipe foam and attach it to the bottom of your sword using the same angle edge from before.

  

  This should extend a little past the end of your pipe.

  

  Stuff the end with small pieces of foam and tape it closed.

  

  
  

  

  Here is the finished end thrusting tip. You want to poke a LOT of holes in the end with a pin. This allows air to get in and out of the end.

  

  Do this to both ends. To test that you have done a good job, crush your thrusting tip. If it immediately springs back into form, you have enough holes.

  

  We did not have grip tape to finish the handle. You are going to take hockey grip tape and wrap it around the grip of the sword (the part that just has crappy ducttape and pipe showing.) DO NOT USE DUCT-TAPE FOR THE GRIP. It will give you blisters and will look SHITTY! (Decorative Grips Coming soon!)

  

  Here is your finished sword (sort of.)