The Armour Archive

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Low pro's are pretty easy, once its explained.  

Supplies:
Strapping tape.
Blue foam.
Nylon webbing.  This one is important.  I've tried blue jeans, which don't work as well, and some people use leather (but I find it too rigid).  I'd like to try some silk, but for now nylon webbing has the best strength to low weight ration.   I typically just pick up 15 yards of the stuff at Wally-World (about $0.70 per yard) 


1) Cut out about 2 blue foam circular disks (1.25" in diameter).  If the sword is significantly bigger than 1.25", make the disks the size of the sword instead.  FYI, I have a tool I made to make cutting out the circles faster.  A hole saw (like on the drill attachment would work too).  Btw, if you want to be more kind, use 3 blue foam disks... 2 Fulfill's ansteorra's rules.
2) place disks on top of each other like so 

___________________________________
|                                  |
|__________________________________|
|                                  |
|__________________________________|
|                                  |
|__________________________________|

|------------1.25"-----------------|


2b) (optional) I have epoxyed each disk together before, and it seems to make the whole device act like one unit. Your mileage may vary.

3) Tape with (strapping tape) together by wrapping around the the top so that a side view looks like this :

  ___________________________________
|            |      |                 |
|____________|  T   |_________________|
|            |  A   |                 |
|____________|  P   |_________________|
|            |  E   |                 |
|____________|______|_________________|

4) rotate the tip 90 degrees and tape again.

5) Now, from the top, the circle should have a cross going over it of strapping tape.

6) Attach the tip to the end of the rattan using several (2 to 4) or the top loops of strapping tape over the top of the thrusting tip.

7) Before covering with duct tape, cut two 6" to 8" long strips of nylon webbing Like in step six, attach the strips over the top of the tip to the shaft to help provide lateral bend resistance.  Best results so far have been using this method.  Pay particular attention to the strip that goes in the "edge" orientation, as this will receive the most stress from cutting.  A way to minimize this (I haven't tried this but it just occurred to me) would be to make the strips 45 degrees off the cutting edge so that both strips of nylon webbing would resist tearing.

8) Take the strapping tape and starting 2 or 3 inches from the end of the rattan, spiral the strapping tape up to the top of the thrusting tip.

9) spiral wrap down from the top of the thrusting tip.

10) Cover with duct tape (remembering to follow your kingdoms rules if it specifies color).

Only difference in my construction on two-handed weapons is that

a) Use 4 or 5 2" circular disks
b) I add a support ring under the disks to help keep them from folding over.