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<blockquote data-quote="Baron Opal" data-source="post: 2314529" data-attributes="member: 10433"><p>Right, sorry.</p><p></p><p>Here is how I made my last sword.</p><p></p><p><u>The Blade</u></p><p></p><p>I bought two fiberglass kite poles from a local kite shop. These are available by mail order. One is about 3/8 in diameter, with the second pole able to snugly fit inside the first. These run about $5 a piece. This allows you to have a thinner core while still cutting down on the whip. Use some closed cell foam for the blade edges. I use some blue foam camping sheets. They are about 3' x 6' and are normally used under your sleeping bag. You can get several sword's worth of foam for about $6-10. Cut two strips about 1.5 inches wide and 38 inches long. Cut two more 1 inch wide and 37 inches long. Run some sports tape along one side of the 1 inch faom strips.</p><p></p><p>Put the two kite poles together and cut to a comfortable length. I like 36 inches for the blade, an inch for the hilt-space, and 6-10 inches for the grip. Put the wide foam strips to either side to form the edges of the blade. Tape together just enough to brace. Put the narrow strips above and below to cover the fiberglass core. There should be a couple of inches of foam at the tip to form a thrusting tip. Find a large needle and some waxed thread and sew the two narrow strips together, making sure that the thread passes through the wide strips. This will tie the strips together around the core. Sewing makes the sword stronger than if the pieces were glued together. When the foam is stressed, it will tear around the glued pieces, but stretch around the stiching. The paper tape gives the foam a bit more integrity so that it is easier to sew and the stitching doesn't tear through. Sculpt the blade as desired.</p><p></p><p>Cover the blade with some lycra swimsuit material of your choice. This is kind of expensive, but long lasting and it seems to have a lot less air resistance than other fabrics. You sew a sock that fits over the blade.</p><p></p><p>Avoid duct tape for use in the blade. It makes the blade foam stiffer, which is not desireable. </p><p></p><p>Part Two later</p></blockquote><p></p>
[QUOTE="Baron Opal, post: 2314529, member: 10433"] Right, sorry. Here is how I made my last sword. [U]The Blade[/U] I bought two fiberglass kite poles from a local kite shop. These are available by mail order. One is about 3/8 in diameter, with the second pole able to snugly fit inside the first. These run about $5 a piece. This allows you to have a thinner core while still cutting down on the whip. Use some closed cell foam for the blade edges. I use some blue foam camping sheets. They are about 3' x 6' and are normally used under your sleeping bag. You can get several sword's worth of foam for about $6-10. Cut two strips about 1.5 inches wide and 38 inches long. Cut two more 1 inch wide and 37 inches long. Run some sports tape along one side of the 1 inch faom strips. Put the two kite poles together and cut to a comfortable length. I like 36 inches for the blade, an inch for the hilt-space, and 6-10 inches for the grip. Put the wide foam strips to either side to form the edges of the blade. Tape together just enough to brace. Put the narrow strips above and below to cover the fiberglass core. There should be a couple of inches of foam at the tip to form a thrusting tip. Find a large needle and some waxed thread and sew the two narrow strips together, making sure that the thread passes through the wide strips. This will tie the strips together around the core. Sewing makes the sword stronger than if the pieces were glued together. When the foam is stressed, it will tear around the glued pieces, but stretch around the stiching. The paper tape gives the foam a bit more integrity so that it is easier to sew and the stitching doesn't tear through. Sculpt the blade as desired. Cover the blade with some lycra swimsuit material of your choice. This is kind of expensive, but long lasting and it seems to have a lot less air resistance than other fabrics. You sew a sock that fits over the blade. Avoid duct tape for use in the blade. It makes the blade foam stiffer, which is not desireable. Part Two later [/QUOTE]
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