Old Tech: Constructing a stabbing sword

This is a really old technique for making a stab-legal sword. it's really iffy as to whether one will pass, though certain makers have been known to produce very high-quality swords using this method.

For more recent technology, see Constructing a Stabbing Tip

Materials

Core material (either kite spar or fiberglass rod)
3M 90 Spray Adhesive or DAP contact cement
Duct tape
Grip tape (NOTE: optional, used for wrapping the sword handle)
½” wide strapping tape (with the fibers running through)
Sharp serrated knife or utility knife
Metal rule (preferably 4’)
Hack saw
Sharpie marker
½” thick high-density (NOT Walmart!) closed-cell foam
½” thick yoga mat foam (NOTE: low density open-cell or closed-cell foam may be substituted)
1/4" rope (NOTE: optional, used for wrapping the handle)
Beer cozy
Approx. 2 1/2” cube of high-density open-cell foam (an Edhellen arrow head makes a good stabbing tip.)