Step 1: Summary
Not recommended for under 8 years old, anyone who decides that the sword is best used with the wooden handle end out, or going up against professional baseball players. I have not had any injuries for the past 3 years with up to a dozen teenaged boys going at it at once. Still???
Step 2: Gathering the Materials
The 60 inch long Monster funnoodles are easy to obtain at Toys R Us, Sports Authority, or most pool places. Other brands of large pool noodles can be used as long as they are dense foam with a regular cylindrical shape and has a one inch hole in the middle.
The smaller, regular funnoodles (2 3/4 inch diameter with a 3/4 inch hole) can be made for smaller kids but use a 1 inch diameter dowel and a 6 inch handle.
The dowels and Loctite epoxy can be bought at Home Depot.
Epoxy is the best and does not melt the foam. I have found no other glue to hold up (Elmers, woodworking glue, etc). A friction fit will ALWAYS work loose leaving the user with a billy club instead of a sword. Drilled holes and wire ties rips the foam to shreds.