Pantheon LARP

The first thing you want to do is determine the size of your weapon. Blades, hafted, and wooden weapons are 24"+ while small weapons and most improvised are 24" or smaller.  So, for our example, let’s say we’re making a blade that we’re mostly going to use in one hand and we want it to be 36". We’re going to measure out 30" of foam and the other 6" will end up being open cell foam ends.  After you measure and cut your PVC, tape the ends with one or two pieces of electrical tape to close them off. 
Next, figure out where you want to put your grip. Find what’s comfortable in your hands and mark off the area, giving an extra ½" or so on each side. The shorter side should be at least 1"-1 ½" long.

Now, place your closed cell foam next to your weapon and align the end with your marker notch on the blade end. Measure about ½" beyond the blade end on the foam and cut to that point. Spread a generous amount of adhesive on the inside of the foam and slide it onto your PVC. It should fit tight, but don’t worry if it feels a little loose, that’s what the adhesive is for. Tape your foam closed by using some duct tape along the length.

Using some electrical tape where the foam meets the grip, secure the two together.
Next, place your closed cell foam next to your weapon and align the end with your marker notch on the pommel end. Measure about ½" beyond the pommel end on the foam and cut to that point. Rinse and repeat just like we did for the blade end.
Now, using your open cell foam you’ll make the ends of the blade and pommel. Cut two pieces of about 2" thickness and the same size as your PVC. Fill both ends of the PVC with extra open cell foam and then tape your tips onto the ends.

Almost done! Now we have to cover the entire weapon in duct tape. We encourage you to make neat designs and styles, just keep in mind the material of your in game weapon. A bow or club wouldn’t be steel and a sword wouldn’t be wood.  Gray and black are fine for metals, white for bone or unarmed, and brown for wood.

After you cover your weapon in duct tape use either a small pin or something pointy and thing to poke holes in the length of the blade, the tip, and pommel. This gives the weapon room to squish and breath.

Note: For weapons like axes, maces, and hammers make your striking head out of open cell foam and affix it to the striking end of the weapon with duct tape.  Make sure it is tightly connected to the boffer. Also, for staves and polearms use a single long piece of PVC pipe completely encased in closed cell foam with about 1/2" - 1 1/2" extra on both the top and bottom. Use the same guide for pommels on both ends.

And that’s pretty much it. If it turns out well and staff approves it, congratulations! You’ve made a legal boffer weapon. Don’t be worried if your weapon doesn’t pass inspection, it takes some time to get the hang of making boffers, just keep at it!