Hello again, and welcome to part three.  This time I'll talk about
the glorious process of making a sword.  This is not easy, but if done
correctly, can be pulled off with reletivly no trouble.  I'll start by
listing the materials.  First is a bag of 1/2" diameter 5/8" wall
thickness foam pipe insulation. Then you'll need some 2" thick open
cell foam.  That's the really squishy kind.  Then you'll need some 1/2"
diameter pvc plastic piping.  And last some fiberglass and duct tape.
If this already sounds to hard or expensive for you, I make weapons of
all kinds except any of the blunt weapons for between $5.50 for anything
up to 2-handed swords, up to $7.00 fo polearms without a head.  This is
actually cheaper if you only plan on making 1 or 2 weapons as you have
to buy MUCH more pipe, tape and insulation than you will actually need.
    First I'll list some of the weapon chart with size specs and damage.
                                   IN INCHES
                        BLADE LENGTH       OVERALL LENGTH
WEAPON                  MIN      MAX       MIN        MAX        DAMAGE
--------------------------------------------------------------------------
DAGGER                  8        17        12         24            1
THROWING DAGGER         -        -         12         19            1
SHORT SWORD             18       24        26         32            2
LONG SWORD              25       36        34         44            2

    Enough of that though.  On with how to make it.
    First you cut the pipe to 6 inches less than you weapons overall
length.  Then cut a 4" piece of insulation for the crossgaurd if you
have one.  Slide that up the the pipe till you reach the point at which
you feel comfortable with the amount of gripping area there is.  Then
measure how much pipe there is left on the blade.  then add 1" to that
and cut a piece of insulation to that size.  Then VERY CAREFULLY slide
that down.  It will be a TIGHT fit so be VERY CAREFUL!!  The insulation
rips EASILY when doning this.  Then cut a 1 1/2" piece and slip that 1/2
way over the pommel. (End by your hand)
    There, with the hard part done, this should go quicker.  Take the
open cell foam and cut 4 peices the size of the OUTSIDE diameter.  Make
sure that they are circles.  Now use the fiberglass tape to FIRMLY tape
the crossguaed in place.  Then use the duct tape to tape the open cell
foam over the four points of the sword.  (The pommel, blade tip, and the
two sides of the crossguard.)  Make sure to do it so that it will be
able to squish down and up easily.  Then use a pin or needle to put
holes in the tips.  That will help it be softer and come back out
quicker.
    Then coat the blade with duct tape.  Make sure to go UP AND DOWN the
blade, NOT around it.  That would make it both toooooo heavy and toooo
hard.  Then repeat this on the crossguard.  And last do this to the
pommel.  Make sure to leave enough to go all the way down the grip.
That's how it will stay on.
    Have fun trying to make your sword.  And if you can't or just don't
want to, remember I will for $5.50!

                        SEE YA'
                                Walter Berry