Mod Shop – Melee Sword

A few weeks back I went along to my first solely melee based game here in Canberra with a group called The Hundred Swords. After thoroughly enjoying myself in game, I decided it was time to refresh my melee armory with a few new weapons that better suited their rules. First up was a 110cm one handed sword.

I’ll run through what I’ve done for this sword but of course feel free to take the basic principles here and apply it to basically any other weapon.

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Tools/Materials required…

Foam floor mat
Fibreglass rod
Hot glue + gun
Duct tape
Yoga mat


We’ll kick off with the floor mat.

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Trim the jigsaw pieces off the sides.
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For the length I wanted, three strips just happened to be the perfect length. I then decided to have them 70mm wide.
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Trace the width of the fibreglass rod with the knife to make a small cut, only a few mm deep.
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Then hollow that out as best you can. I found a screwdriver to be about the perfect tool for this.
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We need the core to be able to sit nicely in the channel we’ve just dug.
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After we’ve done two of the floor mats, the core should sit flush between them. You can see here that I’ve done a little too deep at this end.
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For the third piece make sure to leave some of the matting full width in the middle. There needs to be some solid matting at the very end of the weapon to make sure the core can’t easily puncture right the way through.
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Tape the end piece of floor mat to one of the other two.

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Then lay the rod in place.
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Wrap some tape around the end of the core to make sure there are no sharp edges that could cut into the matting. photo DSCN8063_zps65d0b9b0.jpg

Then run some glue for the length of the channel, lay the core in place, place some heavy things on it while it sets.

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Fold the top piece over, tape the final piece of floor mat in place, then run some glue along both the core and the face of the matting so that all three surfaces will be stuck together. Be careful not to use too much glue or get it too close to the edge as the glue will dry hard and won’t be fun to be hit with.
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Now we’ll handle the handle….
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Cut a small hole next to the core, fill it with glue and insert some rope.
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Run some glue along the handle then wrap the rope around the core. Make sure that it is as tight as possible.
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At the end, trim the rope to the correct length.
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Close it off with some tape.
And I’ve missed a photo here but use some of the offcuts from the floor mats to make a base. Make sure that it adequately covers/protects the core as you don’t want it getting speared into anyone.
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Again using some floor/yoga matting off cuts, make yourself a tip.
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Use a very small amount of glue to hold them together.
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Cut a strip of yoga mat the same width as the thickness of the ‘blade’ of your sword. This is softer than the floor matting and will provide a nicer surface to be hit with.
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Glue/tape the start of it in place.
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Run some glue along the ‘blade’.
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Then tape at varied intervals.
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And below we should have the almost finished product.
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Wrap the whole thing in tape to give it a protective top layer but be careful not to wrap it too tight. If you completely compress the yoga mat it will effectively provide no padding.
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And there we have it. One foam sword, perfect for melee fighting.


One thought on “Mod Shop – Melee Sword

  1. Not bad man, looks clean and concise. I plan on making one of these myself in the near future, to compliment my home made shield.

    This will certainly aid in the brainstorming department. Kudos on an easy to read write up, and a sexy looking melee weapon.

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