by Randy » Wed May 02, 2012 2:23 pm
Take your .505 core. Cut it to size. Using around a 1/2" wide 2 inch long stip of foam and medium strength clear plastic tape, create what is commonly known as a biscuit. You tape 1" of the foam onto the core and allow the other inch to cover the tip of the core. Torque wrapping the foam in both directions. This should create a semi-firm foam insert between the core and what will become your stab tip.
Then using the camp pad-esque foam at UFO, (remember 1/4" not 1/2" thickness) and either DAP contact cement OR super 77 (DAP is preferable), you cut the foam to desired striking edge length. Tape the edge of the core to the edge of the foam and tightly roll the foam until the diameter of your weapon is 2.6". Then using a straight edge, cut what will become the width of the foam at a 45 degree bevel (bevel towards the core) along the length. Unroll, and add Dap/super 77 to what is the inside of the foam. Again tightly roll the foam around the core. Using plastic tape, add a four lines of horizontal tape on the bottom, middle, and top of the weapon. At this point I generally wait a week for the glue to dry, not required but its what I do. Using 3/4" yoga mat, cut into 2.6" diameter circles as your stab tip and clear plastic tape to secure the tip and protect the foam along the striking edge. Finally add a good cover and build your handle/pommel appropriately.