I love sword play, but not the limited selection of foam or padded swords sold. PVC and pipe insulation are fine, but the swords you can make with them are limited. However, with a bit of plywood and a saw, you can make custom sword of any shape or size.
*Disclaimer: Swords of any kind are dangerous! This sword is padded but it WILL hurt if you get hit hard. Never use it to hurt another living being or someones property! I am not responsible for what you do with these instructions! They are ment only for informational purposes!*
Step 1: Tools and Materials
To make a sword using this method you will need:
A scroll saw or jigsaw (I used a scroll saw, but for larger blades a jig saw is better)
A Rotary tool with a sanding head and a cutting head
3 1" screws (you may need more depending on the blade size)
1/2" PVC pipe
Foam pipe insulation
Optional but recommended:
Large graph paper
Step 2: Design The Blade
Using this instructable you can make a sword shaped however you like. To start I find that it is helpful to estimate the length of the blade. Doing this will give you a base to work off of. Draw the shape of the blade however you like. The finished product will have about 1/2" of foam on the edge so make your blade smaller than you want the finished product to be. If the blade has complex turns it will be hard to add the foam, but it is not impossible to do. The handle will be 1/2" PVC so you don't need to draw it. to attach the PVC there dose need to be a 1/2" wide support where you want the blade with at least 1" of wood above it. I recommend that it is at least 2" long.