Sorry for the lousy quality of the photos, I just took them and it's nighttime and I don't light the house very well and was too lazy to adjust the images.
This is a pretty classic boffer sword, as a rapier. It's a length of PVC pipe. Around the pipe is the pipe insulation. You can get two kinds of that, a rubbery neopreny-like kind and a thicker kind. The second type stings a little less but makes a fatter sword. For a gentler one, use pool noodles. There are two kinds, solid ones and ones with a channel through the middle. Get the hollow second kind and you can just shove (with difficulty) the PVC up through it. You might have to wait 'til summer to find them for sale, though.
Cut your insulation or pool noodle so that it is longer, by a few inches, than the sword blade. When you assemble it, leave that extra length at the tip so that it's well padded there. Otherwise, you'll hurt somebody even if you forbid jabbing, because the hard end will scrape them if you just barely whiff.
The basket hilt on this one is two plastic coffee-can type lids glued together with the kind of hard-core rubber cement like you use for patching inner-tubes.
The handle is unpadded. You can see there's a little cuff 'round the end that's another peice of padding. You can make a cross-hilt, with a T-junction PVC plumbing peice and some short bits of pipe. Pad that, it's not as easy on people as the coffee-can-lid basket hilt.
Once assembled, it's just covered with duct tape. In this case the silver and black, but now you can get red and blue too and make them look different if you want. It looks nicer if you run it lengthwise. Overlap a lot. Eventually the adhesive on the tape will harden and it'll peel off 'cause the padding is flexing under it, and you'll have to strip it off and re-tape it.
Here is Isingrym, the boffiest boffer of all time. You can hit somebody as hard as you can with that, and knock him off his feet, and the part of him that'll hurt is his butt where he landed. You can see it needs to be retaped. It's really old. If kids want to play with them I'll give the bigger one this ax. The blade is a peice of couch-cushion foam. There's pipe-insulation on the top part of the handle and on the end. The spike at the top is another peice of pipe insulation, it's totally hollow and just has V-shapes cut out of the top so it folded together into that shape. It's too hard though, and a jab with that does sting a bit. It used to just have a spike there cut from the couch-cushion foam, but eventually it tore off. You could make a cartoony shaped big poofy sword by cutting couch-cushion foam like that. You can cut it pretty rough, the duct tape will make it look better. The only trouble is cutting the hole through it to push the PVC in. I used a long carving knife for this one. Just remember to leave plenty of padding space at the end.
You might want to use the black ABS piping instead of PVC, it's softer. But it'll warp and you'll get curvy swords if you don't store them hanging up.
Last edited by Electric_Kite on 18 Dec 2008, 10:12 pm, edited 1 time in total.