Building a Dagorhir sword

This should work for both PVC and fiberglass cores; The illustrations show fiberglass core.

(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:

Pair fiberglass rods together and duct tape together.
Secure tip of core so it doesn't poke through the padding.

Padding:

*Note about contact cement: Apply to surfaces to join lightly and allow cement to dry to a "tacky" texture before joining surfaces.

Glue two 1-inch wide strips of closed cell foam together (just one strip would work as well, depending on the thickness of the core) and to the sides of the core as shown with contact cement.
Glue a 2-inch wide strip of closed cell foam that covers over both sides of the blade.
Repeat last step until the blade is covered with three layers of closed cell foam on each side.

Grip:

Place a popsicle stick on either side of the grip with the bottom cut flat. Leave about a penny's diameter of the popsicle stick to reach over the bottom to extend the handle length a little if necessary.
Place 40-50 pennies between popsicle sticks and on bottom of handle for a counterweight. The balance point of the length should be 2-4 inches above the thumb when holding the sword.
Secure counterweight and sticks tightly with duct tape.
Cover counterweight with a thick 2-inch wide block of open cell foam and a 2-inch wide strip of closed cell foam and secure tightly with duct tape as well as the bottom of the blade padding as shown. Remember, the pommel cannot pass through a 2 1/2 i nch diameter hole to be considered safe.

Cover:

In a pinch, this part can be bypassed with a sock.

Take a piece of cloth 4-6 inches longer and 3 times as wide as the blade and fold in half.
Sew along top and side of cloth, cut off excess leaving a 1/2 to 1-inch hem and turn inside out. (for best fit, wrap cloth around blade and pin cloth along sewing lines)
Cover blade with cloth and secure bottom of cloth with duct tape.

Cross guard:

There are many ways to make a hand guard from the rapier's bell guard to the katana's tsuba. It should be foam and safe. This part illustrates a basic cross guard.

Place a 1 1/2-inch wide, 6 to 9-inch long strip of closed cell foam above the grip with a block of open cell foam between the overhanging strips.
Secure and wrap with duct tape.

... and there you have it.

-Scion d'Ur