Constructing a Glaive

Originally taken from Eriador's construction site.

Materials Needed

Bandshoppe pole
DAP Contact Cement
3M 77 Spray Glue
Blue camp pad
1/2 large nerf football (Ensolite)
5/8" Pipe Insulation
3/8" Pipe Insulation
Duct Tape
Black cloth tape
Cover fabric, preferably trigger

Instructions

WARNING

Glaives are among the most dangerous weapons on the field. Due to the fact that they are two handed, are long, heavy, and frequently swung quite hard to break shields, great care must be taken to ensure that they are constructed safely and sturdily. Glaives are not a good project for beginner foamsmiths.
These instructions are intended for experienced foamsmiths, and are left sparse for expediency.

Steps

Cap the pipe, using either a PVC endcap (for PVC cores), a good pipe cap (for bandpole cores), or a quarter (all cores). Be sure the cap is securely held on with strapping tape. Tightly tape down a small scap of foam on top of the cap.
Box the core. Be particularly careful to glue well at this stage.
Once the first box is secure, put on a second box.
Add the blade. This can be two sided or one sided, by preference. There should be at least 3 layers of closed cell foam on top of the double box and one or two more on top.
Attach half of large nerf football using spray glue or carpet tape. Cut it to shape, and cut off the tip so it does not pass more than .5" through a 2.5" hole.
Use lengths of Duct Tape or Strapping Tape to secure the football to the tip. Spiral short lengths first clockwise around, then counterclockwise. In the end it should be completely covered in Xs of tape. Also, add haft padding.
Reinforce the tip by gluing a piece of foam around the entire tip.
Cover, pommel, and you're done! If you only have a single striking edge, be sure to mark the back edge with contrasting tape.

Variations

For a potentially safer but larger glaive, instead of using three layers of blue foam for the blade, put down one layer of blue, one layer of 1" ensolite, and at least one layer of closed cell on the outside.
These instructions show a single-edge glaive. These are lighter than double-edged glaives, but slightly less versatile and more prone to being grabbed in line fighting.
People have successfully experimented with various marine foam rubbers to make thinner, lighter glaives that are still safe. These foams need to be evaluated and used on a case-by-case basis.