This tutorial (view PDF) is my attempt to help those who have not made any L.A.R.P. weapons learn the process. This is the main method that I use to make weapons in the Myth Wood. Other Foamsmiths have other methods. If you ever have a question feel free to get ahold of any of us Foamsmiths, we love to help out. Shared ideas can only make our weapons better.

What you will need.

1. Roll of blue camp mat. (I get them at Wal-Mart)
2. Dap contact cement. (Wal-Mart, Menards, Fleet Farm.)
3. Gorilla tape, duct tape.
4. Cord, clothes line, or any string like material.
5. Razor blades
6. Tape measure, ruler, yard stick.
7. 1/2 inch fiber glass core. (Fleet Farm, 5 foot length.)
8. Washers that fit your 1/2 inch fiber glass core. (Fleet Farm)
9. Yoga block, or some other closed cell foam.
10. Double sided carpet tape. (Menards)
11. (Optional) Popsicle sticks. (Wal-Mart)
12. (Optional) Hockey tape.
13. (Optional) sand paper, but I strongly recommend it. (I use 80 grit.)

Step 1, you draw up your idea for a weapon in a notebook, or whatever works for you.  Then draw it out on the foam camp-mat. This style is a “sandwich” method. This means the weapon is being built in layers.  For our weapons in the Myth Wood this means a three layer minimum for the striking surfaces.

Step 2, is to cut out all your layers. Inspect them to make sure everything lines up the way you want it to.

Step 3, is to pick the middle layer and cut out the center so that the 1/2 inch fiberglass core fits.  You want this to be as snug a fit as possible. Check the core to be sure that what you have cut out is lining up properly.

Step 4, is where you cut a piece of yoga block to replace the very tip of the center layer. The tip should be a minimum of one inch in length.  This is done to make sure that the fiberglass core does not punch through the foam and into your opponent.

Step 5, following the instructions on the can of Dap, you use the dap to adhere the center layer to the layer before it as well as the fiberglass core.  This involves putting a thin layer of dap on every surface that will touch another. Waiting ten to twenty min for the dap to dry, very carefully put the pieces together in the way you want them. Make sure the fiberglass core is dapped to the foam. You want a strong tight bond between the fiberglass and the camp-mat. You do not want any wiggling or areas where the fiberglass is not in full contact with the camp-mat.

Step 6, you dap the center layer to the piece after it.  Your end result should be three layers of camp-mat that look roughly sword like dapped together with a fiberglass core running through the middle of it. At this point you should sand all the layers even and try to get all the rough look cleaned off.

Step 7, if you have any more layers that you have cut out to give the weapon depth or character, now is the time to dap them to the main body of the weapon.

Step 8, you cut a strip of camp-mat the thickness of your three layers, or however many layers thick you have made your striking surface, and as long as the outside area of the weapon (striking surface). Dap this all the way around the outside edge of your weapon.

Step 9 cut away any of the fiberglass core you will not need.  You can do this beforehand but I wait until now just in case plans change during assembling it.

Step 10, tape it up.  I did not include many pictures on this because everyone does it differently. I gorilla tape any striking surfaces and any areas that need more reinforcement. Then I go and add any of the color tapes I think will make it look good. Finally I put good old gray duct tape on any edged areas. Just the way I like to do it.

Step 11, figure out how you how you want the weapon balanced. Add the number of washers you feel will be needed. Secure them how you see fit. I dap, and gorilla tape them in place.

Step 12, cover the washers with camp-mat. You can go fancy or plain, but make sure at least one layer of camp-mat is covering all strikable sides of the washers.

Step 13, wrap the handle area in double sided carpet tape. If you like you can add popsicle sticks at this point. It will change the grip on your weapon. Now wrap the handle with string or rope. Add as many layers of rope as you want until the handle is the size you would like. I then cover the rope with hockey tape.

Step 14, cover the pummel with duct tape, and your done.

As I said before this is only one method.  If you find a better way please share with the rest of us.  This method however will make you a safe and reliable weapon.  It should also be pointed out that as these weapons get used they wear out.  For the most part this method is very easy to repair, and rebuild.