John's Guide to Making Boffers

John's Guide to Making Boffers (click on the link for an explanation)

Necessary Supplies:

PVC Pipe Cutters

PVC Pipe (sch 40, 1/2in for 1-handed weapons, 3/4in for 2-handed) Pipe Insulation

Duct Tape a Sharp Knife

Step One:

Decide what kind of weapon to make, and cut the pipe to the appropriate length.

Step Two:

Put a piece of duct tape over one end of the pipe, to keep the edges from cutting into the foam insulation.

Step Three:

Being careful to NOT split the seam in the foam, slide it over the pipe, leaving enough bare pipe for the crosspiece, a handle, and the pomel (the width of your hand plus about 3 inches; More for two handed weapons).

Step Four:

Cut the end of the foam off, two to three inches above the end of the pipe.

Step Five:

Cut a piece of foam for the crosspiece, as long as you want, but not less than 4 inches.

Step Six:

Use the end of the pipe to cut a hole through the center of the foam, and push the crosspiece up against the blade. Save the two circles cut from the foam for later.

Step Seven:

Cut two pieces of foam for what is politely referred to as the 'Q-tip' at the end of the blade. These should be at least 3 or 4 inches, but can be as long as you want. Cut the seam on these pieces, pull them open and wrap them around the end, covering the area where the pipe ends. If necessary, cut one of the pieces to make it fit better. Use a piece of duct tape to hold it in place.

Step Eight:

Turn the crosspiece so that the seam on the blade is on the flat of the blade, and lay duct tape along the blade, starting on the pipe below the crosspiece. Continue the tape up over the Q-tip and down the other side, ending just below the crosspiece. It is a good Idea to mold the tape around the Q-tip.

Step Nine:

Wrap tape around the crosspiece and blade as shown, to keep the crosspiece from breaking during use.

Step Ten:

Repeat step 8, but around the ends of the crosspiece and up the uncovered part of the blade. You may have to cut the corners of the tape to get it to lie correctly.

Step 11:

Cover any remaining uncovered areas on the crosspiece and Q-tip.

Step 12:

Cover the open end of the pipe with duct tape.

Step 13:

Cut a piece of foam 1 to 2 inches long for the pomel. Slide it onto the pipe, leaving 1 inch of foam past the pipe. Use the foam cut from the crosspiece to fill the end of the pomel, and tape it into place.

Congratulations, you just made a boffer sword : )