I've also posted this on a subreddit but wanted to ask here too, since the local group I'm leaning towards is hearthlight
Before we start, this would be my first foam weapon craft, though I'm no stranger to other crafting. I have watched a bunch of videos, read a lot of guides, I've use gorg stuff as loaners so I know what quality feels like. Ive made a list of modern materials and steps and techniques I feel pretty confident with. But I do have a few questions, and treat me like someone who knows nothing, I'm here to learn. The hilt:. I've seen people do a quick wrap or tennis grips. I've also seen a bunch of cord/twine wraps, but everyone is vauge about what cord/twine they're using, they don't mention material or diameter. I've also seen it done several ways. Can someone clue me in the advantages and disadvantages of: Different materials? I see similar stuff availabke in jute, hemp, nylon, poly, linen. Some are tougher, some are natural, more or less stretchy, etc. are any too tough for the hands? Wear too quickly? Feel better? Different sizes? I think 3mm looked good but I see down to one and up to like 6. Any thoughts there besides obviously the thickness/weight, but like grip-ibility/comfort? Under/over layers? I've seen people wrap leather or foam around the rod then cord over that, Ive seen people do a top layer of leather or cloth, any thoughts on doing an under layer, an over layer, both, neither, is it material dependant, etc? The shape of the blade: The majority of the blades I've seen are simple gorg like rectangles covered by cloth. I did see a few people shape the foam to be more sword shaped, but those ended up being latex or plastidipped. Obviously I'd have to keep a good minimum padding, but any other reasons not to do this? Should I use softer outer layer foam if the edge is a bit thinner because of shaping? Is it near impossible to cover a shaped blade with cloth or is it the same process or....? Or should I really look into plastidip if I wanted a more swordy shape (and does plastidip mean I should use a softer foam to make up for the coating?) Cloth covering - Ive heard trigger cloth is the best if you want to sew it. I've never sewed before but I'm willing to learn, but I'd be doing it by hand not with a machine. The guides just say sew, are there specific threads I should use , specific needles, should I look up any specific type of sewing technique? Anything different if I try and do a shaped blade instead of rectangle? If I just get legging/stocking, anything I should avoid like fleece lined? For counter weighting, I saw several good methods. However, I noticed the rods I was looking at have as an optional accessory some rubberized rod caps a bit over an inch long. I was thinking of just putting whatever weight I needed in the hilt end rod cap before gluing it on, then pommeling over it, seems like a decent plan, right? (Obviously doing test weighting with tape first to get the weight right) Also, I've heard the best grips are ovalish in the direction of the blade, to help you know the orientation. Do most people ignore this and keep it circular, or do you foam wrap then shape the hilt, or how do you best do this? Thanks for all the guidance, I'm leaning hard on your experiences
I do feel the hilt maybe isn't as ergonomic as it could be. I had a 1/2 inch core I used like 3/8 inch dowel rods on either side of, they were pretty close to a straight line but not perfect, attached with DAP. Then I wrapped in electrical tape, then I did a Paracord wrapping. Should I make it thicker next time, with foam underneath? Should I wrap over with thin leather? Make it less elliptical and more round? How do you get great feeling oval
Well, I put together a 4 page guide, compiling all the information from each guide I had read, and spelling out the instructions each time someone used a term I didn't know, so i didn't keep having to swap between guides. Then I got together with my brother and we built a set.
It turned out pretty decent! I just need to let it cure for a week while I sew covers for the foam, then we can test if it will pass, but i'm hopefuly. I learned a lot, I think when I build another I will be able to do it in half the time. And with some improvements - i think i can do the crossguard better, i think i can get a little shape on the blade edges, and the handle should be an inch shorter. I also need a little heavier counterweights than i used in the pommel. But I managed to actually make a crossguard and an oval handle on my first go, and the blade looks and feels ok to me, so thats a win! plus i have all sorts of extras
I've gotten some advice already and thought I'd share here:
I'm told oval handles are better, and commonly people attack 3/8 dowels to either side of the handle via some method (glue, carpet tape, etc) then either do a leather/foam wrap or tape then do the cord.
I've hear 1/8 inch Paracord is common for wraps, but some people cover it if it's too tough on their hands.
I've heard that trigger cloth is no longer made, but 5oz poly cotton poplin is a very good replacement. I'm still looking into what needle and thread to use. I've heard a zigzag stick and/or backstitching is good for a reliable seam.