alternate to box core method?

[LoganSteele]

I have buit my fair share of box cored weapons. I notice on round cores the corners make no contact and there isnt as much surface area for the foam to bind to on as there is on one of those sweet square cores.

I am contemplating experimenting with the core layer by putting on a wrap of blue and cap instead of a box and cap. It would look similar to a layer of incidental padding. Then over this layer i would either apply the blade wraps and one layer of blue along the flats for strength or build an actual box core over the foam (making a double box cored effect) then the blade wraps. I am thinking of this method for reds but maybe it would be useful for blue too. Has anyone tried a method like this? I cant see it being dangerous or failing.

I do see a disadavantage of maybe it being heavier or bulkier than nessasary. Another possible disadvantage i see is the blade may take on a type of curved striking surface that might cause it to hurt more then it should (something i dont want).

I might rebuild my mini red 5/8 solid 50" fiberglass core like this to test it out.

What to you experts think? I like to get your input before i begin something experimental.

[Doozer]

that's very similar to the *GHETTO* progressive density style. you barber poll wrap the core with the blue camp pad, but pull it tight so its thinner.

as far as how well it works...
not sure

[Remdawg Killionaire]

Do a MC EVA lite foam around the core, a layer of camp pad then a layer of EVA camp. Works * good. All the swords I have like that lasted a year(or more!) before I had to fix 'em. Most are still good, I just had to replace the stab tip. Bhakdar made 'em and they've stood the test of time if anything.

[Aimish]

Isn't there a method where you use a router to cut semicircular grooves into the foam to allow full contact with the core?

Certainly not a worth buying a router just for this, but if you already have one you could probably use it if you have/get the right size and shape bit.

[Bran ap Eynon]

Isn't there a method where you use a router to cut semicircular grooves into the foam to allow full contact with the core?

Certainly not a worth buying a router just for this, but if you already have one you could probably use it if you have/get the right size and shape bit.

For this method I had been using a crappy $20 rotary tool that we had laying around the house. It burnt out pretty quickly, but I've now started using a power drill with the rotary bit. It works very quickly, you just need to figure out how to control the drill well enough to get a good cut. Guides will be your friend there, though I've been able to freehand it fairly well so far. I'm still playing around with a few different ways to blade swords this way. An easy one is making a sword fry like the reblade kits from Edhellen/forgedfoam. The big issue I've been having with that way is the tips blowing out on stabbies really early. I'm thinking that having two grooved halves that work more like a box-layer blade may be the way to go for stabbies.

[LoganSteele]

I used a knife to cut grooves on two pieces of foam to core a driveway marker short sword a couple months ago. Its been holding up so far. Certainly something to think about for the larger diamter cores as well.

[barley]

Isn't there a method where you use a router to cut semicircular grooves into the foam to allow full contact with the core?

Certainly not a worth buying a router just for this, but if you already have one you could probably use it if you have/get the right size and shape bit.

This is a very viable method. I make a ton of these. I have not had a tip blow out yet.

The key i found was the foam used in the box layer. Stronger EVA's seem to work much better than camp pad or cross-linked poly. The Edhellen fry makes a superior striking surface tho.

[Ryu]

i actually just recently started using a dremel tool to route for my core in 4lb puzzle mat and use a heat gun to layer on 2 layers of blue to make my blade kits

[Zuloo]

Isn't there a method where you use a router to cut semicircular grooves into the foam to allow full contact with the core?

that is exactly what edhellen does to make their swords