Here are step by step instructions with diagrams and pictures for constructing a long sword.

Materials

• 5' of 3/4" PVC. (Lowes on Capital Circle sells 5' lengths).
• 36" (3 feet) of 5/8" wall pipe foam.
• 3" x 2" x 2" of open cell foam.
• Miscellanious scraps of open cell foam.
• A roll of Duct Tape.
• A sharp knife.
• A tape measure of yard stick.
• A PVC cutter or hack saw.

Sword Stats

The first thing to do is determine the swords stats. Looking back at the sword construction table we see that a sword can be upto 44" long, have a 36" blade and and 8" grip. It must have a 2" thrusting tip and some sort of gaurd and a pommell. It is always better to make it a little small than the maximum so you can be off on some of the measurements. I have decided on a 42" long sword.

Next determine the pommel size, I know this sounds wierd but it helps determine the pipe size. I am going to make a 2" pommell. 1" will fit over the pipe and 1" past it for safty reasons.

To calculate the PVC size take the total length (42"), subtract the thrusting tip (2"), subtract 1/2 the pommell (1") and take off 1 more inch.

42" - 2" - 1" - (2"/2) = 38"

Cut the PVC pipe 38" long.

INSERT PVC Picure.

Take 3 stips of duct tape about 6" long and cut them in half length wise. Use one strip and cover the end of the pipe. Take another and do the same thing except turning it 90 degree. Take a third strip and wrap it around the pipe securing the 1st two. Repeat for the other end.

INSERT TAPE PICTURE

Next determine the foam size to do this we need 2 more measurements, the Gaurd and the Grip. Since we are going to use the same foam for the gaurd as the blade the Gaurd will be 2" high. The Grip wil be 7", for no reason other than its legel. The foam length is the total length (42") minus the thrusting tip (2") minus the Gaurd (2") minus the grip (7") minus the pommell (2").

42" - 2" - 2" - 7" - 2" = 29"

I am assuming you are using the only 5/8" pipe insulation available here wich has a 1" internal diameter, not 3/4". If your not make appropriate allowences. Cut the foam 29" long. Open up the split. Tape your tape measure and draw a line 1/4" to one side of the spilt and the length of the insulation. Cut along this line removing a 1/4" peice of insulation.

INSERT FOAM sliver picture

Now slide the foam around the PVC pipe leaving 1" of foam above the pipe. Using 3 peices of tape about 6" long pull the gap closed. Do not pull tightly. You do not want to compress the foam just close the gap.

INSERT PICTURE gap closing

Now take a longer peice of tape and lengthwise close the entire gap.

INSERT PICTURE gap closing 2