AMTGARD Sword making�(golf club, pipe insulation and camp pad method)

Lord Water Hammer

(Amtgard player, father, and fighter with an eye toward safety, durability and savings for Amtgard players)

Where to start? Get stuff.

I prefer severed golf clubs and pipe insulation.

Where to find graphite golf clubs:

• 1. Thrift store (usually $1-$4 each).
• 2. Dump re-use centers (usually $1 each).
• 3. Golf pro shop’s dumpsters (ask permission).

And my latest and greatest:

• 4. Golf courses themselves (I put out a bin advertising that I was collecting used graphite golf clubs to make Amtgard weapons for a non-profit group that caters to medieval fighting style re-enactment and family fun.) All the ones in the photo came in the bin this week.

Where to find pipe insulation:

• 1. Home improvement stores ($1-$2 for a sixfoot tube 1/2“ thick round a 5/8” hole).
• 2. Plumbing supply outlets (i.e., Grainger) ($9 for a six foot tube 1” thick around a 5/8” hole.
• 3. Dump re-use centers (usually $1 each) varied sizes.

And my latest and greatest:

• 4. Habitat For Humanity Thrift Store ($5 for the nine pieces you see in the photo).

Camp Pad ($10ish from Walmart)

Had to pay full price this time, none in the thrift shops

Packing, electrical, and duct tape �(buy it cheap when its on sale)

Fabric for covers �(two full sheets on clearance from Ikea $5.00)

Cost

• This pile of gear cost $42.50 and should make six short and three long swords. It also cost about 35 hours of effort looking for deals on materials.
• Less than $5 cash outlay per sword.
• Tape will be the highest cost of this build.
• Breakdown:
• Clubs: free
• Insulation: $5
• Pad: $10
• Tape: $22.50
• Fabric: $5

I will build three legal shorts at home and photograph steps.

• Best part: I will build the other six on park days to demonstrate construction methods to all those who wish to watch or do.

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• Shall we begin?

Prep the clubs:

I cut my shafts to no more than 33” so that they will be less than 36” when completed.

Sand the ends to smooth all surfaces.

Prep the tips.

Do not be cheap on this point. Use lots of tape and wrap it tightly.

Place 3 to 7 layers of duct tape over the end and down the shaft to make a smooth tip out of the hollow tip.

Golf clubs have an inherently good back tip if you leave the handle on.

Prep the shaft.

Graphite can splinter when broken. Tape the entire length of the shaft with packing tape to prevent slinters from leaving when the shaft gets broken.

I trim down the handle to just longer than my hand with thumb extended and a 1” space for the pommel to attach (about 8 inches for me).

Prep the shaft.

I frequently invert the second layer of packing tape (sticky side out) to help hold the insulation in place.

You do not need to tape over the remaining handle of a golf club. The wrap should keep the splinters in.

Sticky side out on second pass

Camp Pad compression tip.

• As an added step above the normal three flat layers of camp pad over any stabbing tip or 1.5” of foam, I usually compress a cross of camp pad over the tip to stop the tip from penetrating any foam.

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First layer is under duct tape

First layer of insulation

Cut the first tube down so that is surrounds the core behind the compressed camp pad tips with no rattle. Seal the seam with packing tape.

First layer of insulation

Unite the tip with the insulation with a ring of duct tape.

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Attached the grip end to the grip with a ring of duct tape.

Add the second layer of insulation �(even with the tip)

Second Layer of lateral foam and First un-compressed camp pad cap

Seal the seam with packing tape. You may wish to spray adhesive between the layers of insulation.

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Tape your first layer of uncompressed cam pad over the tip.

Second un-compressed layer on tip

After you have sealed the strips with a round of duct tape, place another slightly larger camp pad piece over the tip and again fasten it down.

Third layer along length

Cover the sword blade again with a third layer of lateral foam, sealing the seams with packing tape. Then place the third and final camp pad cap on the tip and tape it down.

Torque wrap to hold pad in place.

Pommel

Add crossing layers of camp pad to the pommel until it reaches a diameter greater than 2.5”. Cap with a nicely shaped flat piece of camp pad.

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This is the eye protection piece for your teammates (do not scrimp). This also helps balance the weapon (use plenty of camp pad and duct tape).

Grip

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The simplest handle is to tape down the fabric covers with electrical tape. In the Hammer Household we use the green tape to signify weapons that are legal shorts and available for loaners without asking.

The second grip was made by wrapping cotton cord around the shaft (golf grip removed to conserve weight. Orange signifies loaners but with class restrictions, i.e., long sword, reach, and red. This one is a long sword.

(Black is personal weapons, you need to ask one of the Hammer Household before using, but I usually loan those out too.)

Working a little bit each day

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• Weapons in various stages of construction.
• Building 7 Short, 3 long and one reach.

More progress (3 shorts to go).

1lb

7 oz

1lb

5 oz

1 lb 10 oz because of golf club grip

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Just when you thought you were done:

28”

42”

Four more donated clubs showed up and the thrift store was having a half-priced Labor Day Sale which means 7 more swords to make eventually.