There are many methods in boffer sword creation. Through trial and error, this method has proven to create a sword that is both light and durable. Especially make sure that you follow the steps on tape placement, as having any tape along a striking surface is sure to create stress tears and rapidly degrade the usefulness of your sword.

Step One

Cut two lengths of camping foam with the same width as the core you are using.

Step Two

Run a piece of Duct Tape down each side of the sword, securing the foam to the Core.

Step Three

Cut out four pieces of foam the same width as the core and the already attached pieces (combined distance.) Use Duct Tape to secure the pieces at the handle end of the sword only.

Step Four

Cut three to four pieces of foam to place at the tip of the weapon as shown above. This will make your stabbing tip.

Step Five

Run Duct Tape down the length of both sides of the Blade Flat, making sure you do not tape anywhere on the striking surface of the weapon.

Step Six

Cut off the ends of the striking tip to make a generally rounded shape.

Step Seven

Cut a long piece of foam (same with as described in step three). However, this piece needs to be long enough to wrap around the entire length of the weapon.

Step Eight

Tape the foam down in the same manner as step six.

This is how the weapon should look if looking down at it from the handle.

Step Nine

Creating the weapon pommel is in the same method as described in creating the weapon blade. However, you only need two layers instead of three (see above picture - tape as you would the weapon blade.

Step Ten

Covering your weapons are fairly simple. fold a narrow piece of cloth in half (making sure you are using enough to fit the blade of the weapon into) and sewing it down. Make sure that you sew in a round fashion at the tip so that the blade cover will fit snuggly against the foam blade.

Now you have a sword ready for weapons inspection!

Note: this method will work on nearly all cores that you may use, I normally add an additional layer in Step Three for “Red Weapons”