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How to Make a Boffer Spear

Though some may dismiss the spear as a commoner's weapon lacking the glamour of the sword or the machismo of the axe, the discerning LARPer knows that in the hands of even a moderately skilled warrior, the spear is a truly formidable weapon. There is a reason the spear was the mainstay weapon of ancient and medieval armies, after all, and price had little to do with it. Learn first-hand the advantages of this ancient and noble arm by making and using a safe boffer spear in mock battles with your friends.

Things You'll Need

1 inch thick PVC pipe, approximately 5 to 6 feet long
Hacksaw
Sandpaper
Foam swimming noodle
Mat knife or box cutter
Marker (optional)
Duct tape
Foam pipe insulation

Instructions

- 1
  Cut a length of PVC pipe with a hacksaw at a length you feel comfortable with for a spear shaft. Spears used with one hand will tend to be shorter than those used with both hands. A good intermediate length is a few inches shorter than your own standing height.
- 2
  Sand the edges of the PVC pipe to take off any sharp edges that could cut through the padding.
- 3
  Cut a length of foam swimming noodle, about 15 to 24 inches long, using a mat knife or box cutter. This will be the spear point. Cut another piece about 1 foot in length to pad the butt end of the spear. Although you may not intend to strike anyone with this end, it is important to be safe.
- 4
  Place the spear point foam alongside and parallel to the shaft so that the point protrudes 6 to 10 inches beyond the end of the shaft. Mark the point on the shaft next to the other end of the foam using a marker or a small piece of tape. Do the same with the other end of the shaft, except using the shorter butt pad.
- 5
  Slide the spear point foam onto the PVC shaft just to the point you marked on it. This will ensure there is at least 6 to 10 inches of foam padding between your target and the hard PVC pipe inside. The hole in the middle of the noodle should fit the pipe snugly, and it may take some effort to get it on.
- 6
  Secure the spear point in place with duct tape. Begin with a single long strip that runs parallel to the shaft, starting 6 to 8 inches down the shaft from the foam and running up over the foam tip, then back down the opposite side of the foam to the shaft again. Reinforce this tape where it meets the shaft by wrapping another piece of tape tightly around it, close to the base of the foam tip. Then firmly wrap the entire foam tip in duct tape so that none of the foam is visible.
- 7
  Attach the butt padding foam to the other end of the spear in the same way you attached the spear point in the previous step, also covering it with a snug protective layer of tape.
- 8
  Trim a length of foam pipe insulation to a length that will cover the unpadded portion of the spear shaft. Foam pipe insulation is considerably thinner than the foam swimming noodle, but it will still reduce the chance of injury from blows or collisions with the shaft of the spear, which tend to hit with less force than full spear thrusts on the tip.
- 9
  Secure the pipe insulation to the entire length of the shaft between the padded ends by placing short lengths of duct tape against the shaft, running out through the split in the insulation and onto the outer surface of it. Place these anchors no more than 3 to 4 inches apart, to ensure that the insulation does not slide around the shaft too much as you handle the spear.
- 10
  Wrap the pipe insulation padding firmly with a protective layer of duct tape.

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