How to Make PVC Pipe Swords

Measure off 34 inches of a length of PVC, mark it and cut it off using the hack saw. Be careful to cut it straight. You can carefully use your knife to trim off any jagged edges, although the entire piece of pipe will ultimately be covered.

Place marks 2 inches and 8 inches from one end of the piece of PVC pipe; that end will be the bottom.

Measure out two pieces of the pool noodle, one 30 inches long and the other 4 inches. Cut the pieces off squarely using either the hack saw or your knife, whichever provides you the most personal control. Be careful when using either, and always cut away from you.

Cut two scraps off of the remaining pool-noodle material. One should be 2 inches long, and the other 4 inches long. They should both measure 1 inch wide.

Slide the 30-inch piece of foam onto the forward end of the PVC pipe. This may take a little effort, but twisting the pipe as you thrust into the foam will help. Slide it down until it reaches the mark you placed 8 inches from the bottom. You should have 4 inches of overhang at the top.

Insert the 1 inch by 4 inch piece of scrap foam into the hole at the end of the foam, so that it plugs the hole. It will also serve to keep the PVC pipe from inadvertently slipping through the end when you thrust at your unsuspecting friends.

Tape the foam in place by running a single, long piece of duct tape from the exposed PVC pipe along the entire length of the foam. When you get to the end, wrap over the tip and run the duct tape along the other side until you reach the handle. The duct tape should overlap onto the PVC by 2-3 inches on either side. Run another long strip in the same manner, but allow it to overlap the first piece of duct tape by 1/8 inch. Repeat this process on all exposed areas of the foam until no foam is showing through. Three strips should be sufficient to cover the foam.

Place the 4-inch piece of foam over the handle up to the 2-inch mark. You should have 2 inches of overhang off the handle. This will serve as the pommel, or bottom of the handle. Place the 2-inch piece of scrap foam into the bottom hole to plug it.

Tape the pommel just like you did the blade, overlapping the handle grip 2-3 inches. Remember to cover all exposed foam.

Tape the handle grip in a spiral around the grip, making sure to overlap onto the previous tape to further hold it in place. Add as much duct tape as you prefer. More tape will give a squishier feel, while less will offer a more solid connection with the covered pipe.

Go beat the daylights out of your friends, but remember to arm them too. Otherwise, it just wouldn't be fair.