Don't hurt yourself. Use a boffer.
NOTE: Some techniques borrowed from Will Gray. Youtube: WillGray42
Step 1: Materials/Tools
Some PVC 3/4
Some Pipe Insulation
Coloured Duct Tape (Optional)
Step 2: Cap the Ends of the Pipe With Tape.
Take a little square of tape and pull it tight over the end of the pipe.
Step 3: Pull the Insulation Over the Pipe
Make sure that the perforation in the insulation doesn't come undone. Leave about an inch on the end of extra foam.
Step 4: Make a Core for the Thrusting Tip
The core there so that the pipe doesn't poke through and gore someone. The tape on the end of the pipe keeps the core from sliding down into the pipe.
Step 5: Tape Up the Blade
Make sure it's smooth and has no wrinkles. Leave some anchors on the handle end so that the tape stays. Tightly wrap electrical tape around the base.
Step 6: Tape the Tip
Follow the pictures.
Step 7: Do All Previous Steps on the Pommel.
Go ahead and 'lectrical tape the rest of the handle.
Step 8: You Could Stop Here, But...
It looks like a baseball bat. Follow the pictures...
Step 9: Yay! We're Done!
Go hit your friends with your new toy!