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How to make a duct tape sword


by morfmir on November 18, 2009 Table of Contents How to make a duct tape sword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: How to make a duct tape sword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Things needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: The design and research fase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 3: Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 4: Marking and cutting the foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 5: Putting it all together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 2 4 5 7 9

Step 6: Cutting and shapenig the edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 7: Taping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 8: Making the handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Step 9: Decoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Step 10: The finished sword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Step 11: Kids making swords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Intro: How to make a duct tape sword


This is the second instructable in a series about how to make weapons and other equipment for LARP. My main focus is that the weapons have to be safe, so kids can play with them without direct adult supervision, without getting hurt. And secondly so easy to make, that big kids, with help, can make it them self. These weapons is perfect for a backyard battles or a game of LARP (Live action role play) in the nearby forests. If you keep the design simple it is easy to make, and with adult supervision kids can make their own. The other guides: Battle axe

Step 1: Things needed


You will need Sketch block a pencil A hobby knife, with interchangeable blades. Extra blades Used dull blade a piece of cardboard or paper a black marker a cutting pad contact glue duct tape reinforcement Tape double sided tape Silver tape, for decorations. a sleeping pad 10 cm of foam tube 2 strips of cotton cloth 3cm thick bamboo, fiberglass or a broomstick

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. reinforcement Tape 2. duct tape 3. contact glue 4. a black marker 5. A hobby knife 6. Extra blades 7. cutting pad 8. dull blade from the hobbyknife.

Image Notes 1. double sided tape

Image Notes 1. silver tape

Image Notes 1. look how shiny the silver tape is.

Image Notes 1. a sleeping pad

Image Notes 1. Bamboostick

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. foam pipe for the handle.

Image Notes 1. pencil 2. Sketch block

Step 2: The design and research fase


Start by finding some pictures of "real" swords. Ex. do some google search. http://images.google.com/images?hl=da&sa=1&q=sting+sword http://images.google.com/images?hl=da&sa=1&q=elf+sword http://images.google.com/images?hl=da&sa=1&q=orc+sword http://images.google.com/images?hl=da&sa=1&q=viking+sword http://images.google.com/images?hl=da&sa=1&q=fantasy+sword Now you have enough inspiration to make you own design. Just draw some quick sketches. They don't need to be beautiful, it is just so you will get the idea about how your sword will look like. Don't make the design to complicated. Special the crossguard, it is easy to make a very good looking design on paper but it is difficult to make it in foam and duct tape. My sword will be an elf sword, inspired by Frodos Sting from Lord of the Rings.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. This will be the one I make.

Step 3: Template
Now draw the design of your choice on paper or cardboard. This will be your template so be careful and take your time to make it perfect. If you have problems with making the two sides of the swords identical, fold the paper in half and cut it folded. When you unfold the paper the template will be perfect, and the two sides identical.

Image Notes 1. the small drawing is what I will go for.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. three pieces of A4 paper taped together.

Image Notes 1. I fold the paper when cutting it. To be sure that the two sides are identical.

Image Notes 1. unfolded and ready

Image Notes 1. template for the pommel 2. two templates for the crossguard.

Image Notes 1. to get an idea about how the finished sword will look like, I place the templates like the finished sword.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Step 4: Marking and cutting the foam


Now draw the sword 3 times on the foam. Pay attention to the placing of the pieces so you don't waste to much of the sleeping pad. The small space between the sword pieces is ideal for cutting the crossguard. To be sure the pieces ends the right places I put numbers on them. In the middle piece I cut a hole for the bamboo stick. If the stick for the handle is to long, now is the time to cut it into length.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. one 2. two 3. three 4. outside crossguard 5. inside crossguard 6. pommel

Image Notes 1. place the stick on the middle layer and draw the outline of the stick.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. cut the hole for the stick.

Image Notes 1. The middle layer ready.

Image Notes 1. foam pipe for the handle.

Image Notes 1. cut the bamboo stick into the right length.

Step 5: Putting it all together


On piece 1 and 3 of the cross guard I put a strip of reinforcement tape. This will stabilize the cross guard to ensure that it will not break or be ripped apart. Now apply glue to one side of piece 1 and 3. And apply glue to both sides on piece 2. Also apply glue to the handle. Let it dry for 10-15 minutes, and press the pieces hard together. Be careful the pieces glue together very quickly, so be sure that they are aligned, you will not be able to correct it. The only way to correct it, is by cutting away on the outer side.

Safety note
If your using the same glue I use you need to have good ventilation. If it's not to cold it's best to glue outside. It's possible to get waterbased contact glue if you make this with kids, I recommend using that. But it takes a lot longer to dry.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. reinforced to prevent the crossguard to be ripped off.

Image Notes 1. I apply a thin even layer. And then spread it with the dull hobbyknife blade.

Image Notes 1. ready for the glue

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. Layer 1,2,3 and the inner crossguard glued and pressed hard together.

Image Notes 1. the pommel and the handle glue and drying.

Image Notes 1. outside crossguard glued to the inner layers.

Image Notes 1. inside view of the pommel

Image Notes 1. Sword all glued together. Now it is ready for final shaping.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Step 6: Cutting and shapenig the edges


To make the foam look like a real sword you need to cut the edge. If the layers got unaligned when gluing, this is the right time to cut that edge also.

Image Notes 1. Switch to a new blade in your knife... It needs to be very sharp. With one gliding movement you cut the edge. That way you get the best clean cut.

Image Notes 1. I draw a line where the edge starts.

Image Notes 1. all cutting edge shaped.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. very uneven=not good. Cut the edge to align the layers.

Image Notes 1. Then shape the pommel and the handle,

Image Notes 1. look at the crossguard, it needs to be perfect, if not you will see it through the tape.

Image Notes 1. nice clean cutting edge.

Image Notes 1. all the cut off, save it for later- You will need it if you want to make my warhammer later.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Step 7: Taping
Add strips of duct tape to the sword. Be careful when applying the tape special around the corners. Take the hobby knife and cut the tape into strips so it will not get wrinkled. When applying a new strip of tape, don't make the overlay more than 1 cm. If you put on to much tape, the weapon gets hard and heavy, making it dangerous to play with.

Image Notes 1. ripped 2. cut with hobbyknife 3. see the big difference in the end of the tape when you rip or cut the tape. To get the best result you need to cut every piece of tape. Ripping will make i curled

Image Notes 1. first strip of duct tape

Image Notes 1. make cuts along the places the sword curves. If you don't cuts the strips the edge gets wrinkled.

Image Notes 1. try to make the tape as smooth as possible.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. when the entire blade is covered. Add a strip of tape all the way around the edge.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. Remember to cut the tape into strips so you can fold it even with out wrinkles.

Image Notes 1. cross guard finished.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Step 8: Making the handle


I found a old piece of cotton cloth and ripped it into strips. I covered the handle with double sided tape, and tied the cloth tight around it.

Image Notes 1. double sided tape, usually used for taping carpets to the floor.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. old cotton cloth

Image Notes 1. in the end I split the strip in two and tie a knot.

Image Notes 1. finished and ready for the final decoration.

Step 9: Decoration
I use the black marker to draw some decoration and to highlight the edge to give the blade more depth. I cut some decorations of silver blank insulation tape and put them on the crossguard.

Image Notes 1. Silver tape.

Image Notes 1. I decided to only cover the crossguard with the silver tape. It is very expensive so no need to waste to much of it.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. oh so shiny :-)

Image Notes 1. It really makes a big difference when the edges gets some color. 2. logo of +Ulfberh+t

Image Notes 1. Viking rune saying "made by Ash" Or to be more correct "Ash made" My viking alias is Ask the danish name for Ash.

Image Notes 1. Ready for action :-)

Step 10: The finished sword


Here it is the Elven longsword in all its glory. Look forward to my next instructable in my duct tape weapons guide. Next time I will show you how to make a shield that is safe,beautiful and durable.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. Axe and sword waiting for the kids to take them for a swing :-) 2. The axe is a little battle marked. It has been used a lot since I made it.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. A kite shield, this will be the subject of my next instructable in my duct tape weapons guide.

Step 11: Kids making swords


Here are some pictures of kids making foam duct tape weapons. And some kids playing with swords I made.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. different color the same result.

Image Notes

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

1. Elven dagger... a real girls weapon.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. bicycle tube used for handle, a good alternative to leather or cotton cloth.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Image Notes 1. Arrrrrrr... 2. my first warhammer... No padding on the handle, bad idea. Good I changed my design since then.

Image Notes 1. kids showing of there swords I made for them.

Related Instructables

Pocket Sword!!!!! by vanpaun

Making a custom shaped boffer (foam sword) by xenongamer

Sword (Light amtgard hewing Boffer Dagger spear (Photos) Saber) by The by Travelsonic magical duct tape by corey_caffeine kid

Makeing a amtgard (or boffer) sword. by use606

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Comments
50 comments Add Comment view all 53 comments

canadianrock says:
Thats pretty cool! thanks for all your help, im gonna use that for my Halloween costume!!

Jan 26, 2011. 8:14 PM REPLY

smileys says:

Dec 4, 2010. 6:04 PM REPLY hmmmm.... I wonder if you could do a sephiroth style sword using this method.... better yet cloud's buster sword!!! Oh by the way if you can't tell I like final fantasy....

skittlespider says:

Jan 13, 2011. 9:42 AM REPLY That could work but I see a length/weight issue with those two swords. You will have to put something pretty sturdy under the duct tape

mcpoofy says:

Dec 2, 2010. 1:37 PM REPLY This is so great, I needed a prop sword for a movie I'm making and this makes a great and safe way to shoot an epic battle scene. I've got my layers glued together and I'm ready for shaping. Do you have any tips on carving and shapping? I really need this to look great.

morfmir says:

Dec 2, 2010. 2:36 PM REPLY You can make some engraving with a soldering iron, put the tape a little lose on the relief and highlight the engravings with a marker. Make some tests on a scrap piece of foam to practice. /Thomas

mcpoofy says:

Dec 4, 2010. 4:47 PM REPLY Awesome, thanks! I have a lot of small details that needed to be carved in th middle and I had no idea how to do it, Your soldering iron tip will work great!

Jyssa says:

Mar 14, 2010. 3:45 PM REPLY OMG when I saw the thumbnail of that last pic, of them up against your couch, I thought the items were resting against someone's FINGERS - and I went WTF??? Miniatures?? How the hell do you make those out of foam and duct tape?

333154 says:
YES!!!! me too.

Nov 1, 2010. 12:36 PM REPLY

taria says:
you did too huh? that's what I thought, I was thinking gees he's making swords but they are tiny swords..lol

Jul 12, 2010. 7:48 PM REPLY

anex says:

Apr 15, 2010. 12:32 AM REPLY Good to see you are training the kids in the way of Awesomeness early. Then when they are older they can truly be epic larpers!

seflynn says:
i agree thoes swords remind me of the old larp swords in my group now we have new epic ways of makeing them

Sep 19, 2010. 11:11 AM REPLY

tsukiyomaru0 says:
I'll be sre to use THIS instructable instead of the other one I found in another site! :D

Aug 25, 2010. 10:58 AM REPLY

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

Attamet says:

Aug 18, 2010. 4:58 AM REPLY I made one! the one on the left is mine, the one on the right is my brother's. The method here makes really fun swords that don't hurt at all! From now on I'm making all my swords like this.

morfmir says:
That looks very good. Great design I'm glad that you like my instructable.

Aug 18, 2010. 8:39 AM REPLY

Attamet says:
Very good instructable with awesome results! Keep up the good work

Aug 14, 2010. 8:54 AM REPLY

evenstay2 says:
hey i am wanting to make my own sword and im just wondering is it safe to say that ur foam is about 5mm thick?

Jun 13, 2010. 4:37 PM REPLY

morfmir says:

Jun 13, 2010. 10:37 PM REPLY The foam I use is 8mm. If you can only get 5 mm and you feel that the sword is to thin with 5mm foam, just use 4 or 5 layers til you feel it has the right thickness. /Thomas

evenstay2 says:
thanks =)

Jun 14, 2010. 2:21 AM REPLY

justjimAZ says:

Jun 4, 2010. 2:55 PM REPLY You have done a very nice job with this. I have made many, many foam weapons for various purposes and am very impressed with your results here.

FFVIIBOY says:

Apr 11, 2010. 7:58 AM REPLY well since its suposed to look like Sting and also cuz its a tutorial on makin a sword id like to know if youd join my group the Fellowship of The Ring and put this on PS i am seriously suprised that no one else made a group called the Fellowship of the Ring

seabananers says:

Apr 28, 2010. 12:42 PM REPLY maybye cuz its a straight rip lord of the rings like if you play world of warcraft and make a hunter named Lagolass then people call you a b**** just sayin

FFVIIBOY says:
ahh, kids trying to cut each others heads off with swords the size of their bodies

Apr 19, 2010. 9:22 AM REPLY

Brother_D says:
Wow, these would make some sweet movie props.... Thanks!

Mar 27, 2010. 3:01 PM REPLY

americaneagle says:
i love warhammer yours is awsome

Mar 3, 2010. 5:40 AM REPLY

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

americaneagle says:
for the handle and reinforcing would 1/2inch pvc work as well if i figured out how to pad it

Mar 1, 2010. 7:17 AM REPLY

Mirime says:
Awsome I like it though the girls wepon remark is kind of how shall i say it sexist my sister an i love to sword fight and we made swords out of knex now that was and still is fun!!! Still awesome dude

Feb 3, 2010. 1:31 PM REPLY

skimmo says:
larp is cosplay of roids

Feb 3, 2010. 1:12 AM REPLY

Nostoc says:
The result is quite awesome. I would recommend against using bamboo for the core though.

Jan 31, 2010. 4:48 PM REPLY

When bamboo breaks, it produces sharp ends. Having already seen in LARP people with broken weapons hit once or twice before noticing, i'd use another substance we often use fiberglass rod with floormat foam, and PVC tubing with Pipe insulation.

BgRdDragon says:
Very Cool! It is Much Better Then Your Last Tutorial, and All the materials Can Be found around the house.

Jan 31, 2010. 3:47 PM REPLY

Morningshadows says:
Awesome!

Jan 30, 2010. 5:26 PM REPLY

craftsman says:
what exactly does your runic it spells aitawimui but what does that mean?

Dec 23, 2009. 7:55 PM REPLY

morfmir says:

Dec 24, 2009. 2:20 AM REPLY It means "Ash made". The inscription is known from a lot of iron age and viking findings. The straight lines is not i's it is space. Some times in runes inscriptions you see lines as a divider of words but most times it is dots. The Rune looking like F is not only A but it is also the symbol of the Ash tree. And my viking alias is Ash (Ask in Danish) /Thomas

craftsman says:
That's pretty cool where did you learn all of this

Dec 24, 2009. 3:27 PM REPLY

anthonyman75 says:
the powah of the enterwebs can teach anything, cmon u should know that by now.

Jan 7, 2010. 7:22 PM REPLY

AresPredator says:

Dec 7, 2009. 5:04 AM REPLY Great project and very good looking blade, man. I usually make mine with pipe insulation (see the image below. Not easy for kids, though), but I'll probably use the holiday season to try my hand at making a few weapons according to your model. Good work! (changed the picture below per request)

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

red-king says:
the hilt looks really good.

Dec 31, 2009. 2:55 PM REPLY

Clonebear says:

Nov 30, 2009. 3:35 PM REPLY Thank you for this instructable, Morfmir! This design looks much, much more safer then my wooden swords. They also look better. I have one question: Where can I find that pipe foam? Google just gives me links to Pipe Insulation...

morfmir says:
Glad you can use it. Yes this is very safe, I have no problems in letting my kids play with it with out any supervision.

Dec 1, 2009. 9:20 AM REPLY

The pipefoam I use here is from a sittingpad. But you can use pipe Insulation instead. The reason why I use this kind of pipefoam is only because I could not find pipe Insulation. /Thomas

no swear-man says:
when does the shield come out

Dec 18, 2009. 4:34 PM REPLY

morfmir says:
next week I expect. /Thomas

Dec 19, 2009. 1:15 AM REPLY

no swear-man says:
kewl thx

Dec 20, 2009. 5:24 AM REPLY

P.S. I absoultly LOVE the sword

aborior says:
This makes me smile.

Dec 19, 2009. 7:54 PM REPLY

biggy smalls says:

Dec 8, 2009. 5:39 PM REPLY i prefer galdiator style fighting. i use just a 1" di. broomstick handle and pipe insulation tubing, and foam pommel. they work great and are nearly indestructable.

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

cdude2600 says:
Cant wait for the Shield!!

Dec 8, 2009. 4:40 PM REPLY

MrL33TPenguin says:

Dec 8, 2009. 3:02 AM REPLY Thanks so much for this!! I need to make weapons from the Vikings for Honors and because I don't have a large forge so this is perfect! Thanks for this again :D Dec 3, 2009. 8:37 AM REPLY To be completely honest I first thought that the sword I saw in the thumbnail for this i'ble was a replica sword of sting that would be used as the template, not the finished product. These look utterly fantastic! Cant wait to try and get my younger cousins making blades themselves that way they have some safe swords to wail on one another with, instead of the wooden ones they use now XD Dec 2, 2009. 6:11 PM REPLY Your swords are pretty awesome. I myself have been making some LARP boffer weapons but I use a totally different technique that can be seen in this tutorial. fanwar.com/making_weapons_mastercraft.htm I will take a picture of my swords eventually.

bluesquirrel says:

Juklop says:

MadBricoleur says:

Dec 2, 2009. 5:26 PM REPLY Wow, thanks!! That's really cool. The kids in the last few pictures are really lucky to have someone to make them things like this... :D

kad15 says:

Dec 2, 2009. 5:24 PM REPLY I suggest that instead of cutting it folded (I find it less precise) that you darken your line. Then fold the paper in half so the line is inside. Finnally you should rub the paper with something hard. When you open the paper you will have another line that is simmetrically identical to the one you drew.

cowscankill says:
Cool! I want to hit some people!

Dec 2, 2009. 1:03 PM REPLY

view all 53 comments

http://www.instructables.com/id/How-to-make-a-duct-tape-sword/

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