Updated Blue Sword Tutorial

THIS IS A WORK IN PROGRESS!!! I am using the old pictures as placeholders for now.

Basic Instructions

These instructions are for a beginner level sword. If this is your first weapon, you're doing it right so far by coming here!

Materials/Tools Needed

• 1/2" fiberglass. If you don't have access to any, 3/8" fiberglass or 1/2" PVC will suffice for lengths out to 27" or so.
• DAP Contact Cement
• Blue camp pad
• Strapping tape
• Duct tape
• cloth tape. Most commonly comes in both black and white. Black will not show dirt.
• Carpet tape
• 1/8-3/8" rope
• Cover fabric, preferably trigger
• hacksaw
• Straight edge of some sort, be it a (preferably metal) yardstick, ruler, etc.
• Razor blades. You will need lots of these. Having a fresh sharp edge will help you make better weapons.
• Sand paper
• Permanent marker

Instructions

1) Using a hacksaw, cut your core to your desired length. Keep in mind that about 2" of foam will contribute to the total length of your sword. Most veterans recommend a 30-34" length sword. Mark your desired handle length, allowing about 2 in. for the pommel. Remember that the maximum handle length for a blue weapon is 18 in. or 1/3 of the overall length, whichever is greater. The handle can't be more than one-half (1/2) of the overall length of your sword.

For this one, we're going with about a six inch handle.

2) Sand the sharp edges around the tip of your core, then take a 1/2" x1/2" scrap of foam and place it on top of your core. Using an X of two 1/2" wide lengths of strapping tape, secure this little scrap (commonly referred to by foamsmiths as a "biscuit",) to the top of your core, compressing it about 20-30%. Then, wrap this whole configuration horizontally with a single layer of strapping tape. This process is called "biscuiting" and ensures your core will not cut away at the inside of your sword blade.

Next, sand the entire blade length, including the biscuit assembly. Ideally, you want to sand strapping tape just enough to remove that glossiness. Remove the dust with a slightly damp cloth and dry your core if needed.

3) Cut a strip of blue camp pad that's as wide as your core (3/8" or 1/2") and slightly longer than twice your sword blade. It's important that your cuts are as neat and clean as possible; any wonky cuts in this layer will affect the overall integrity of your sword. This is where having fresh razor blades and a straight edge really helps.

After making several cuts, you may notice your blade dulling and in need of replacement. Razor blades are quite cheap, so don't feel as if you have to be stingy with them!

4) READ THE DAP INSTRUCTIONS CAREFULLY!! DAP one side of your blue foam strips and DAP evenly around your core from the top of your handle mark upwards toward the tip of your blade that you biscuited. When both your core and your foam strip are dry and tacky (about as tacky as a Post-it note), stick the strip onto the edge of your core, starting at the bottom of your blade and going all the way up, over, and down the other side.

Be very careful to make sure this strip is adhered as straight as possible.

5) Cut two strips of blue foam with dimensions as long as and as wide as your blade at this point. Do not worry about rounding the tips of these strips for now.