Sparring Sword
Step by step method for the construction of a simple padded sword for light sparring.
Please bring your comments, questions, and difficulties with these projects to the Numenor Council.
Caution: no sword can be made safe. Wear eye protection and use common sense!
Materials
- 5/8" hardwood dowel
- 5/8" closed-cell pipe insulation
- duct tape
- permanent marker
- yarn or cotton batting
- utility knife
- back-saw
- OPT: string
- OPT: 1-1/4" hardwood dowel
- OPT: drill with 5/8" speed bore
- OPT: hose clamp
Length of Dowel
There are two questions to answer before you start: do you want a long sword or a broad sword, and do you want a separate, reusable hilt? The separate hilt will improve the feel of the grip, but will complicate assembly and require all the OPTIONAL materials listed above. Your answer to these questions will determine the length of the sword blade:
| long-sword | broadsword | |
|---|---|---|
| all-in-one | 44" | 38" |
| separate grip | 38" | 34" |
Assembling blade
- cut dowel to the length determined above
- cut pipe insulation 38" long for any long-sword and 34" long for any broadsword
- Slip the dowel into the pipe insulation, so that the insulation extends 2" past the tip of the dowel
- Using duct tape, securely tape the insulation to the dowel at the handle end.
- Stuff a length of yarn or cotton batting to fill the empty tip of the insulation
- Tape firmly over the tip, pressing the insulation together. This will prevent the dowel from riding foward in a thrust and injuring your opponent.
- Wrap tape around the tip, then, if the insulation is pre-slit, tape around it at 10" intervals.
- Using the marker, draw a line down the slit side of the insulation. Make sure this line is not toward your opponent when you strike, to prevent the dowel bursting through the slit. (if the insulation is not slit, you may wish to draw a line to represent the edge, for practice's sake.)
- OPTIONAL for all-in-one swords: you may wrap the handle tightly with string or cord to improve the grip.
IMPORTANT! This sword is designed for light sparring, so that those without body armor may safely practice. It will break eventually. Immediately cease use when the dowel breaks, as a broken dowel may have a sharp edge that could drive through the foam and cause serious injuries.
Repairing broken swords
If the insulation is not torn, replacement of the sword is simple: cut through the tape binding the insulation to the blade, pull out the dowel, and insert a new one. Torn insulation may be repaired with duct tape, however, if the damage is extensive it should be replaced.
Re-usable handle
- Cut the 1-1/4" dowel to 6" for a broadsword or 8" for a long-sword
- Drill a 2" deep hole in the center of the end of the dowel
- Carefully cut this hole in half, so that the dowel looks like a tinker toy. I.e.split the end of the dowel
- Wrap the grip in cord or string if desired.
- Pommels and guards may be added, but are beyond the scope of these instructions.
- Insert an assembled blade into the handle and secure with the hose clamp. Do not glue it into place, so that the blade can be easily removed for replacement.
