How to Make a Foam Fabric Covered Sword

A foam-and-fabric sword is great for role playing and children's play. It is sturdy enough to jump around with and hit another foam-and-fabric sword, but it is soft enough to not injure any of the players. You can make the fabric sleeve in any color or design you want to represent yourself. This project requires very few supplies, and the supplies you need are inexpensive. Start to finish, it should take about an hour and a half to make this foam-and-fabric sword.

Difficulty: Moderately Easy

Instructions

Things You'll Need:

• Duct tape
• Foam pool noodle
• 1/2-inch diameter PVC pipe
• Box knife
• Fabric
• Needle and thread or sewing machine

1. Cut a 2-foot section of the pool noodle. Cut a 1-foot section of the PVC pipe.

2. Cut open the pool noodle using the box knife. To do this, cut halfway into the noodle so it opens like a hot dog bun. Cut out approximately 1/4 inch of foam from each side of the bottom 4 inches of the noodle.

3. 
    

   Lay the PVC pipe down so that last 4 inches of the pipe is in the groove you cut out of the foam noodle.

4. Wrap the foam noodle around the PVC pipe and secure it with duct tape. Make sure the PVC pipe cannot be pulled out of the noodle.

5. Measure the fabric so you have enough to completely cover the foam portion of the sword plus 1 inch.

6. Fold the material in half so that the outside is facing in.

7. Sew the material along each long side and one short side.

8. Turn the fabric right-side out to create a long sleeve. Slide the sleeve over the foam. It should overlap the handle of the sword by about an inch.

9. Secure the end of the fabric sleeve with duct tape by wrapping the duct tape around the fabric and the handle.

Tips & Warnings

• You can also take a chunk of the foam and duct-tape it to the end of the handle to create a stopper. This will prevent the sword from flying out of your hand while you are fighting.
• Don't extend the PVC pipe too far into the sword because it will make the sword harder when you hit someone with it.