How to Make a Safe Foam "Boffer" Sword

Step-by-Step Guide

1. 1

   Step 1: Cut your pipe.

   Make sure to subtract 2 or maybe 3 inches (7.6 cm) from the total since your pommel will be 1 inch (2.5 cm) and the tip can be anywhere from 1 to 2 inches (2.5 to
   5.1 cm).
2. 2

   Step 2: Mark off where the handle will be.

   Don't forget to leave some room for a pommel on the end. ,, From the end it should look like this: |O| , You are going to tape them to the pipe, making a box of foam around the core (the pipe). , The wider, 1 1/2" pieces will be the "flat" and the thinner pieces the "blade". , You can bevel this a little since we're going to be putting strips of foam around it for a blade in the next few steps. , For example, a 20" blade and an end cap 2" wide would need about 43" (both sides and end cap +1").
   
   Apply that to the "blade" on one side with the double sided tape, across the top, and down the other blade. ,, Now the sword is 1 1/2" thick on the blade, but only 1/2" on the flat.
   
   Cut 2 pieces that will go up the flat side that is about 2" wide and stops before it goes over the tip of the sword.
   
   Tape those on the flats. , You can also tape the tip to the last flat pieces you added to provide some stability. , Make an end cap and attach that.
   
   Then do it again with a 1 1/2" wide strip, this time wrapping over the previous piece of foam and cap that off with an end cap. ,, To do so make 2 or 3 strips of 1" wide foam that are longer than your sword is wide, cut a hole in the center and a slit on one side of the hole.
   
   Open the slit and slide over the handle and tape to the handle and blade. ,,
3. 3

   Step 3: Starting from the top of the handle

4. 4

   Step 4: measure to the end of the pipe and cut two pieces of foam pad that long and 1 1/2" wide.

5. 5

   Step 5: Put your double sided tape in the center of these pieces and put them onto the PVC pipe opposite each other.

6. 6

   Step 6: Now cut 2 more pieces the same length but only as wide as the space between the other two pieces.

7. 7

   Step 7: Cut a block of foam to put over the end.

8. 8

   Step 8: Duct tape the end to prevent the pipe end from scratching the foam and then tape down your end cap.

9. 9

   Step 9: measure up each "blade" and across the top

10. 10

    Step 10: and cut a 1 1/2" wide strip that long (allow about an inch more to be safe).

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    Step 11: Do this at least once more

12. 12

    Step 12: re-measuring since the size will have changed.

13. 13

    Step 13: Cut two more pieces.

14. 14

    Step 14: Now wrap a little regular duct tape around the base (not too tight)to hold it together.

15. 15

    Step 15: To make a pommel

16. 16

    Step 16: wrap a 1" wide strip around the handle and attach with double-sided tape and wrap in regular tape.

17. 17

    Step 17: Wrap your pommel in Duct tape and use grip tape to tape up the handle.

18. 18

    Step 18: (OPTIONAL) You can add a cross guard if you like.

19. 19

    Step 19: Slip the two trouser socks over the blade and tape them to the crossguard and/or handle.

20. 20

    Step 20: Go enjoy some safe foam combat.

Detailed Guide

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