How to Make Foam Swords

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Fantasy role-playing and historical war re-enactments are a must-do for some people. There are several organizations dedicated to live-action role playing. In order to be involved in the games, you will need to have a weapon. The type of weapon you need will depend on what kind of games you will be playing. Many people enjoy using swords in role-playing combat, and since real weapons will not be permitted, you will need to create a fantasy weapon of your own.

Things You'll Need

  • 2.5' to 5' PVC pipe, 1/2" in diameter
  • 2.5' to 5' PVC insulation
  • Open cell foam, such as a sleeping pad
  • Duct tape
  • Handsaw
  • File
  • Utility knife
  • Penny
  • Cut the PVC pipe to the length that you want using the handsaw. A short sword is considered any blade with a length of 15 to 25 inches. A medium sword is between 25 and 30 inches and a long sword is anywhere from 30 to 60 inches.

  • File the ends of the PVC pipe to ensure there are no jagged pieces. Tape a penny to the end of the sword; this will keep the tube from poking through the foam. The penny should be on the end opposite the handle.

  • Take the utility knife, and cut the PVC insulation foam to fit the pipe. Leave between three and six inches on the bottom of the sword to make the handle.

  • Slide the foam over the PVC pipe. Leave an extra inch of foam at the top of the sword, so that when the pipe is covered, you will have one extra inch of foam that is not covering the pipe. This is a safety precaution and is optional.

  • Tape the foam to the sword lengthwise. Use a four by four inch piece of open-cell foam to cover the jabbing end of the sword. Tape around this foam until it is entirely covered.

  • Cut a piece of PVC insulation in a four-inch by four-inch piece to create a pommel. The pommel is located on the handle end of the sword. This is entirely optional. If you decide to make a pommel, tape over this piece until it is covered.

Tips & Warnings

  • If you want to customize the sword further, you can create a hilt to put between the pommel and the base of the sword. You may also elect to sew a cloth covering for the sword.
  • If you are using the sword to role play at a fictional battle or war re-enactment, you will not be allowed to use a sword that has broken tape or PVC showing as these are safety hazards for other players.

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