Christo The BULL wrote:Could I use expansion foam inside the tube (pvc, or banner pole) cores?
Some people fill golf clubs with an epoxy resin so they essentially become regular fiberglass rods. Expansion foam will break and shatter. It will add nothing to any weapon except little pieces that will rattle around. Don't use PVC for cores.
Further, I believe using shaped expansion foam as a " semi-solid" base to join the softer foams to could be a cheaper practice (in theory one could wrap this with "glass" cloth and epoxy creating your own fiberglass similar to the way surfboards are made).
It's not cheaper or less work than a $1.88, 4' length of 1/2" round solid fiberglass from the farm supply store.
One could carve the semi solid "core" into interesting shapes,
That would have stress points on all the angles.
I believe with proper proportions one could, in theory, Form a reusable "sword base" that requires only softer foam replacement.
We already have these. They're called cores.
As flexibility is a concern I can think of one or two methods of making the "core" less rigid.
We want some rigidity to prevent failing the flex rule. Our current, cheap, and accessible cores do this perfectly.
However why bother with a full explanation when the subject could be mote... I am very new to this, and very "crafty" lol, please, your input would be very welcome.
This game has been around decades. Smarter people than either of us have asked the questions and tried everything under the sun. Things like this don't work or aren't worth the time and money required when compared to readily available and cheap, mass produced cores. The whole idea is moot.
Stick with what works. Go out to a practice and speak w/ your vets. Listen lots and absorb. Limit your questions to things they talk about or you see on the field, not these creative ideas of yours. You'll understand why if you listen and think about how the game works.
When you're ready to build, make some swords under a vet's tutelage. When you think you've got the process down, make a dozen. If they all pass, you're ready to start building other conventional weapons and shields. When you can do that regularly, then you're ready to try unconventional stuff in a safe way that doesn't waste time, materials, or money because you understand game and foam smithing mechanics.
Welcome to the game. Be safe, be honorable, and have fun.