How to Make a Duct Tape Sword

Intro: How to Make a Duct Tape Sword

This is the second instructable in a series about how to make weapons and other equipment for LARP.
My main focus is that the weapons have to be safe, so kids can play with them without direct adult supervision, without getting hurt. And secondly so easy to make, that big kids, with help, can make it them self.

These weapons is perfect for a backyard battles or a game of LARP (Live action role play) in the nearby forests.
If you keep the design simple it is easy to make, and with adult supervision kids can make their own.

The other guides:
Battle axe

STEP 1: Things Needed

You will need
Sketch block
a pencil
A hobby knife, with interchangeable blades.
Extra blades
Used dull blade
a piece of cardboard or paper
a black marker
a cutting pad
contact glue
duct tape
reinforcement Tape
double sided tape
Silver tape, for decorations.
a sleeping pad
10 cm of foam tube
2 strips of cotton cloth
3cm thick bamboo, fiberglass or a broomstick

STEP 2: The Design and Research Fase

Start by finding some pictures of "real" swords. Ex. do some google search.
http://images.google.com/images?hl=da&sa=1&q=sting+sword
http://images.google.com/images?hl=da&sa=1&q=elf+sword
http://images.google.com/images?hl=da&sa=1&q=orc+sword
http://images.google.com/images?hl=da&sa=1&q=viking+sword
http://images.google.com/images?hl=da&sa=1&q=fantasy+sword

Now you have enough inspiration to make you own design.
Just draw some quick sketches. They don't need to be beautiful, it is just so you will get the idea about how your sword will look like.
Don't make the design to complicated. Special the crossguard, it is easy to make a very good looking design on paper but it is difficult to make it in foam and duct tape.

My sword will be an elf sword, inspired by Frodos Sting from Lord of the Rings.

STEP 3: Template

Now draw the design of your choice on paper or cardboard. This will be your template so be careful and take your time to make it perfect.
If you have problems with making the two sides of the swords identical, fold the paper in half and cut  it folded. When you unfold the paper the template will be perfect, and the two sides identical.

STEP 4: Marking and Cutting the Foam

Now draw the sword 3 times on the foam. Pay attention to the placing of the pieces so you don't waste to much of the sleeping pad. The small space between the sword pieces is ideal for cutting the crossguard.
To be sure the pieces ends the right places I put numbers on them.
In the middle piece I cut a hole for the bamboo stick.

If the stick for the handle is to long, now is the time to cut it into length.

STEP 5: Putting It All Together

On piece 1 and 3 of the cross guard I put a strip of reinforcement tape. This will stabilize the cross guard to ensure that it will not break or be ripped apart.

Now apply glue to one side of piece 1 and 3. And apply glue to both sides on piece 2. Also apply glue to the handle. Let it dry for 10-15 minutes, and press the pieces hard together.

Be careful the pieces glue together very quickly, so be sure that they are aligned, you will not be able to correct it. The only way to correct it, is by cutting away on the outer side.

Safety note
If your using the same glue I use you need to have good ventilation. If it's not to cold it's best to glue outside.
It's possible to get waterbased contact glue if you make this with kids, I recommend using that. But it takes a lot longer to dry.

STEP 6: Cutting and Shapenig the Edges

To make the foam look like a real sword you need to cut the edge. If the layers got unaligned when gluing, this is the right time to cut that edge also.

STEP 7: Taping

Add strips of duct tape to the sword. Be careful when applying the tape special around the corners. Take the hobby knife and cut the tape into strips so it will not get wrinkled. When applying a new strip of tape, don't make the overlay more than 1 cm. If you put on to much tape, the weapon gets hard and heavy, making it dangerous to play with.

STEP 8: Making the Handle

I found a old piece of cotton cloth and ripped it into strips. I covered the handle with double sided tape, and tied the cloth tight around it.

STEP 9: Decoration

I use the black marker to draw some decoration and to highlight the edge to give the blade more depth.
I cut some decorations of silver blank insulation tape and put them on the crossguard.

STEP 10: The Finished Sword

Here it is the Elven longsword in all its glory.

Look forward to my next instructable in my duct tape weapons guide. Next time I will show you how to make a shield that is safe,beautiful and durable.

STEP 11: Kids Making Swords

Here are some pictures of kids making foam duct tape weapons. And some kids playing with swords I made.

Comments

[hanelyp]

What, if anything, keeps the core from digging through the foam at the tip?

[Dovakin]

I tried to make the Skyrim steel sword, and this was my end result.
Whist making it, I used a Yoga mat instead. Because of the thinness of the yoga mat, I had to double the middle layer. I also found hot glue and scissors to be more effective.
Bamboo core, PVC piping handle (wrapped in hockey tape), and shiny silver duck tape I found at Walmart!

[dwade9]

All you need is Lydia to carry 500 of those around for you!

[morfmir]

Hi Dovakin

You sword looks good. Glad to inspire you.

/Thomas

[Silas D]

VERY AWESOME!!!!! I am about to make one!

[gaudopippo]

very nice, I had a sword like that, but I did not use the tape, I painted the sword with 10 coats of latex and acrylic paints ;)

[Andrewsruth50]

Legos

[DarkenedHer0.]

made a single edged sword only without the rod support had to make the blade wide enough so it does not break when swung if made to thin will still break

[snozzle1]

nice job i'm going to make a katana with this technique

[SahilS]

one of zoro's or a different one?

[slindblad]

I wanted to make this for me and my friends, could you use 1/2 in.cpvc pipe to replace the bamboo rod? or will the pipe make it more dangerous?

[Dovakin]

PVC piping is alot more flexible! It shouldn't affect the force. PVC piping is a great choice!

If your worried about hurting people, add more foam. Or if you have lying around, a yoga mat to do a thinner layer.

[pentechguy]

I've used pool noodles for the padding and 1/2" SCH 40 pvc for the core. Noodles have a tendency to deteriorate over time more than the camping pads, but are a little cheaper. for the longer weapons (Pole arms, axes, spears, etc.) I go with 3/4" SCH 40 PVC to reduce whippy-ness, but add extra padding for the weight. I like the beveled edges you can make with layers of camp padding though.

[Zender cool]

cooooooooooooooooooooooooooooooooooooooooooooooooooooooooooooooooooool and how do you make it

[umashadi]

U could make a ninja kantana out of this. All ur 'ables are Viking related. Nice.

[Jyssa]

OMG when I saw the thumbnail of that last pic, of them up against your couch, I thought the items were resting against someone's FINGERS - and I went WTF???  Miniatures?? How the hell do you make those out of foam and duct tape?

[The Rambler]

Haha, I had the same thought too.

[scistone]

Oh, I see. LOL HAHAHAHAHAHAHA

[Portalman]

YES!!!! me too.

[taria]

you did too huh? that's what I thought, I was thinking gees he's making swords but they are tiny swords..lol