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GLENDORI.TXT
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1995-07-26
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The Glendorian Sword
The Glendorians were a Aratari Dagorhir Unit that existed between
1983 and 1987. This sword design is from the late Glendorian Era. Newer
technologies have come along since then, but these instructions can still
produce a fine workable Dagorhir sword. Remember, just following the
instructions is not enough to guarentee a safe weapon. Each weapon should
be tested through a series of impacts getting gradually harder. If the
weapon could cause bruses or injury, it is unsafe and should not be used!
Although this weapon is much more difficult to build and maintain
than the traditional Dagorhir pillow sword, the better handling and greatly
enhanced realism are for many people worth the time and expense.
Materials:
('X' is desired blade length; ideally between 18 and 30 inches
for this design.)
(X+6)" section of 1/2" PVC or 3/4" CPVC plastic pipe for a core.
X" x 3" x 1" sheet of stiff closed cell foam. (a foam known as
EVA works well)
X" x 2" x 1/2" strip closed cell. (ensolite or EVA)
X" x 28" x 1/2" sheet of open cell foam. (fairly dense)
(X+4)" x 18" sheet of sturdy cloth. (preferably white, grey, or
black)
duct tape. (cloth tape, not the flame-resistant stuff)
Construction:
1) Slit the X" x 3" x 1" sheet of foam lengthwise from one end
to within a half inch of the other, widening the cut to pipe width
at the closed end.
____________________________________________
| |
| _____ |
|-------------------------------=====_____| |
| |
|____________________________________________|
_______ _______
/ I \
\_______I_______/
End on view
2) Spread contact cement in the slit, and on either side of the
core for an equal length.
_________v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_v_
|___________________________________________________|
^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^ ^
^,v = locations for contact cement
3) Once the contact cement has set (about 20 minutes), place the
core in the foam, pressing the cemented surfaces together. Reinforce
the bond with strips of duct tape across either face of the blade, as
shown.
+-----------------------------------.________
| |
_________I_________________________________________ |
|___________________________________________________| |
| |
| ________|
+-----------------------------------'
+-----------------------------------.________
| ## ## ## ## ## ## ## ## ## ## |
_________I_##__##__##__##__##__##__##__##__##__##__ |
|___________##__##__##__##__##__##__##__##__##__##__| |
| ## ## ## ## ## ## ## ## ## ## |
| ## ## ## ## ## ## ## ## ## ________|
+-----------------------------------'
# = duct tape strips
__________________
/ / \ \
\_______\__/_______/
End on view
4) Tape strips of 1/2" closed cell along both sides to cover
exposed pipe. Also put an extra layer of open cell at the tip of the
core. Use extra strips of tape to reinforce the tip, a vulnerable
spot if too flexible.
+-----------------------------------.________
| ## ## ## ## ## ## ## ## ## ## |
_________|------------------------------------------+ |
|_________| | |
|------------------------------------------+ |
| ## ## ## ## ## ## ## ## ## ________|
+-----------------------------------'
+-----------------------------------.________
| #%% ##%%## ## ## %%# ## %%# ## #%%%%%%%
_________|--%%---%%-----------%%------%%--------%%%%%%%
|_________| %% %% %% %% | |
|--%%---%%-----------%%------%%--------%%%%%%%
| #%% ##%%## ## ## %%# ## %%# ## __%%%%%%%
+-----------------------------------'
% = next layer of duct tape
______
_____/______\_____
/ / \ \
\_______\__/_______/
\______/
End on view
5) Cut two 5" X 18" strips of the open cell foam and tape them
around the edges of the blade. They should be taped to each other
across the 1/2" closed cell, but the tape should not extend around
the edge. The end and flat views should be as shown.
+-----------------------------------.________
| ## ## ## ## #######
_________|--##-------##-------##------##--------#######
|_________| ## %% ## ## ## ## |
|--##-------##-------##------##--------#######
| ## ## ## ## __#######
+-----------------------------------'
____________________
/ _____/______\_____ \
/ / / \ \ \
\ \_______\__/_______/ /
\______\______/______/
End on view
6) Wrap the remaining sheet of open cell around the blade and
tape in place. Tape it over the top and bottom, but it is best if
it is not taped directly to the blade underneath. This allows it
to be slid off later if necessary.
___________________________________
| `--------+
#### ## ## ## ## ## ## ## #####
_________#### ## ## ## ## ## ## ## #####
|_________|-##---##---##---##---##---##---##---##--##--|
#### ## ## ## ## ## ## ## #####
#### ## ## ## ## ## ## ## #####
|___________________________________.--------+
______________________
/ ____________________ \
/ / _____/______\_____ \ \
/ / / / \ \ \ \
\ \ \_______\__/_______/ / /
\ \______\______/______/ /
\______________________/
End on view
7) Pack shredded foam into the core, filling it halfway down from
the tip. Slide a few weights down on top of it, so that the sword
weights about 12 ounces. The required weight is at least 1/2 ounce
per inch of length, and when the last few additions are made, this
should be about right. Fill in on top of the weights with more foam
to keep them from sliding around inside the PVC. Then use about three
layers of the open cell scraps to make a pommel. This should be at
least 1 1/2" wide when complete.
/====================================/
/ foam ((PbPbPbLeadPbPbPb)) foam /
/====================================/
Inside PVC pipe.
___________________________________
| `--------+
__ #### ## ## ## ## ## ## ## #####
/# \________#### ## ## ## ## ## ## ## #####
|#####_______|-##---##---##---##---##---##---##---##--##--|
\#_/ #### ## ## ## ## ## ## ## #####
#### ## ## ## ## ## ## ## #####
|___________________________________.--------+
8) Stitch the cloth into a flat tube, as shown, and slide it onto
the blade. Tape down at hilt.
_______________________________________________
{\ ` |
{ | : |
{ | : |
{ | (inside out) : |
{ | : |
{ | : |
{/..........................................' |
{_______________________________________________|
9) If desired, make a cover for the pommel as well. A wrapped
leather grip is helpful also, both aesthetically and functionally.
___________________________________________
| \
__ | |
/ \ | |
| ZZZZZZZZ| |
\__/ | |
| |
|___________________________________________/
The completed sword should look somewhat like this. There should be
no point on the blade at which the core can be felt. It should not
leave bruises, break bones, break noses, or even hurt very much when
swung full force. The best test is to give it to a friend and have
him/her hit you with it as hard as he can. If it is unsafe, you will
know. If it passes the test, it is ready to use.
The sword will need minor repairs every few months of use, and most
need to be completely replaced after about two years. How long a
weapon will last depends heavily upon how one fights and careful one is.