So you want to make an Energy sword. If you like halo it is fun to have your own boffer energy sword. For those uninformed a boffer is a piece of PVC pipe covered in pipe insulation and wrapped in duct tape. This project took me about an hour but for those new to boffer making could take upwards of 2 hours. I'm sorry there are a distinct lack of pictures but I made this without an instructable in mind. The Total price is somewhere around 10 bucks. I am not responsible from any burn injuries sustained from the water. Let's begin shall we?
Step 1: Materials
6 ft of 1/2 " pvc pipe
2 6 ft lengths of 1/2" pipe insulation
Blue, purple tie dye, or aqua marine duct tape
one large pot
Step 2: Beginning the Bends
First mark the center of the pipe. Then mark the spots 4" on either sides of the center. This will form the handle. Fill the pot with water and start boiling it. when hot, start pouring water over the 4 inch marks with the ladle. this could take awhile. Then, once hot enough, begin bending the pipe so it forms an 80 degree angle. do the same with the other mark. don't worry about keeping the handle perfectly straight we will fix this later.
Step 3: The Blade
about 5" up mark a spot on both ends to bend. bend these points away form each other using the pouring technique so they run parallel to each other.
Step 4: The Handle
if the handle is too curved for your liking, simply dip ONLY the handle into the boiling water and flatten it against a table top.
Step 5: Adding the Foam
take the pipe insulation and start shoving it down onto the pipe until it reaches about 2" past the handle. to make it angle back cut of the ecxess of the foam at an angle and turn it around and tape it back on. do so with both blades. if you want extra support, place a small piece of plpi in between the pipe and tape it down.
Step 6: Duct Tape
Run the tape down along side the foam to cover it all. make sure you do not compress the foam or else it isn't usable for fighting. wrap the handle in electrical tape.
Step 7: That's All Folks
Basically, that's it. Do what you want with it. If you plan on fighting with it, be sure to modify the design to fit your group's rules. Have fun.