(there are quite a few images so it may take a while to load.)
Special thanks to Scion d'Ur for this incredible contribution in developing these pages,
instructions, and splendid graphics. While this design is not the only one
allowed or in use, it is a recognized standard highly recommended for safety and
longevity.
Core:
Start with a 1" PVC core at least 6-7' in length.
Padding:
*Note about contact cement: Apply to surfaces to join lightly and allow cement
to dry to a "tacky" texture before joining surfaces.
Cover the length of the core with pipe insulation except for the grip.
Wrap the spearhead and pommel with enough closed cell foam to mount half
of a nerf football onto. Add two or so circles of closed cell foam to cover
the tip.
*Note: for a halberd striking edge, consult Axe page.
Glue half of a nerf football (or shaped open cell foam) onto spear tip and
add one last layer of closed cell foam around existing closed cell foam and
slightly around the open cell foam to reinforce the tip's structural
integrity.
Cover:
Cut and sew cover spear head like a sword and use a "tube" of
cloth to cover insulated shaft. Secure cloth ends with duct tape.