How to Make a Boffer (Foam Sword)

Step-by-Step Guide

1. 1

   Step 1: Gather your supplies (See Things You'll Need section) 2.5–5 feet (0.8–1.5 m).

   x 1/2" PVC piping (found at a home improvement store, e.g. home depot) 2–4.5 feet (0.6–1.4 m). fun/pool noodle or PVC insulation a.k.a. "closed cell foam" packaging tape or duct tape open cell foam (e.g. couch cushion, sponge, sleeping bag padding) grip tape optional
2. 2

   Step 2: Cut the PVC with a hand saw into the desired size.

   File both ends of the pipe so that neither end is rough.
   
   Place the penny flat against the tip of the boffer (opposite of where the handle will be) and tape it in place.
   
   The penny has a greater surface area than the tip of the PVC and will make it less likely for the PVC to poke through the padding. ,, Leave at least an inch of space in between the end of the pipe and the end of the foam as a safety measure. , When you reach the end, make sure to put a chunk of open-cell foam (about 4"x4") onto the tip of the boffer, and tape over.
   
   Do this as many times as it takes to cover the foam. ,,
3. 3

   Step 3: Cut the closed cell foam with scissors or a utility knife into the right size.

4. 4

   Step 4: Slide the foam onto the PVC all the way

5. 5

   Step 5: so that no PVC shows out one side of the foam.

6. 6

   Step 6: Tape the foam

7. 7

   Step 7: putting one end of the strip on the handle of the sword right before the foam

8. 8

   Step 8: and taping it length-wise across the "blade."

9. 9

   Step 9: Repeat this process with a small piece of closed-cell foam on the opposite end to create a pommel; this is optional.

10. 10

    Step 10: Finished.

Detailed Guide

About the Author