Presented by:
the Shinai Club of Ewing Township
Weapons
They are made of a PVC core wrap with thick foam padding.
Below are instructions on one way to make a boffer sword.
You will need the following supplies to create
up to 2 long swords, 3 medium swords, or 10 Daggers
and/or short swords:
1 Funoodle� (Pre-cored if you can find them)
1 10� x 1/2� CPVC Pipe (PVC is fine)
2 1/2� CPVC End Caps per weapon to be made
1 Racquetball per weapon to be made
1 Franklin� Yard Lawn Ball (Sold in packs of 3)
1/2 yard fabric of your choice for cover.
PVC Glue (Optional)
All-purpose Hobby Cement (or Contact Cement)
Scissors
Hack Saw
Duct Tape
Spare foam/pipe insulation/Funoodle� chunks
Substitutions can be made at your discretion,
but for purposes of this �how-to�, we will assume you
have the above materials and are making a pair of 3�
swords. This design can easily be adapted to
produce flails, axes, hammers or almost any other
one-handed Amtgard weapon. Feel free to elaborate,
but always remember: SAFETY FIRST! Keep your
weapons as short as you are comfortable with. The
longer the core, the more �whippy� and subject to
breakage your weapon will be.
1) Cut 2 30� lengths off of the PVC. This will leave
you with about 5 feet for later projects and/or
additional weapons.
2) Coat the ends (about 1/2� of each) in PVC cement
or contact cement. Press endcaps onto pipe with a
1/2 twist to insure good adhesive coverage.
3) Cut 2 30� pieces off the Funoodle�. It should
leave you with 1 30� piece for later projects and/or
additional weapons.
4) Cut the Franklin� Yard Ball in half. It easiest to
use the �forming line� as a guide and use sharp
scissors.
5) Cut a 3/8�-1/2�hole in the Racquetball. Use
scissors and BE CAREFUL. This can be harder to
do than it sounds. You may find it easier to use an
X-acto� Knife.
6) Apply cement to 3/4 of the total length of the PVC
with endcaps (core) from step 2. Apply adhesive
evenly. �Globbing it on� will make it dry slower
and bond less durably.
7) Slide the core into the Funoodle�. If you have a
solid Funoodle�, cut a slit down one side and lay
the core in like a hot dog in a bun. Leave about 8�
showing for the grip and pommel.
8) If you used a solid Funoodle�, tape the seam shut
with the core inside.
9) This SHOULD leave you with a �gap� near the
stabbing tip of the sword. Plug this securely with
spare foam. It should be glued into place at the top
of the core. Tape OVER it with a piece of tape to
prevent slippage during use.
10) Glue the 1/2 Yard ball from step 4 to the top of
the weapon. Tape it securely over the top and
around the edge.
11) Tape the bottom of the Funoodle� to the core.
12) Tape the Racquetball (or sufficient padding) to
the pommel. (Bottom of �sword�).
13) Slide the cover over the top of the sword and
tape to grip.
14) Wrap grip to taste.
15) Most foam weapons tend to deteriorate quickest
at the tip, so be sure to have tape on hand when
you use your sword for quick repairs. Take your
new sword out to the park and find some unsuspecting
Amtgarder to try your new weapon out on!
