Belegarth

So, I haven't built my own weapon since 2007. I used to by Edhellen (now Forged Foam), then a local foam smith started getting my business.

Anyway, I'm looking to get back into foam smithing, I used to enjoy taking raw material and building a nice weapon out of it. I assume dap and fiberglass haven't changed... I'm looking to get away from blue.

What's the updated foam tech we're using these days?

Where's the best place to get it online?

How should I layer it for best results?

A guy called Alric from Dagorhir sells all kinds of stuff. He sells routed 4lb boxes and 2lb mc fries pretty inexpensively. And he's in Florida.

Teej wrote:So, I haven't built my own weapon since 2007. I used to by Edhellen (now Forged Foam), then a local foam smith started getting my business.

Anyway, I'm looking to get back into foam smithing, I used to enjoy taking raw material and building a nice weapon out of it. I assume dap and fiberglass haven't changed... I'm looking to get away from blue.

What's the updated foam tech we're using these days?

Where's the best place to get it online?

How should I layer it for best results?

I've only been back less than a year myself, but the biggest thing I've seen is the 4# box around core, which adds a nice balance and feel. It supposedly improves durability, but I haven't been back that long.

As far as glue goes, rebuilt a couple swords right before Battle for the Ring about ten days ago using a spray glue (don't remember the brand, but it had a 77 something on it). It was lifechanging, and I don't know that I will ever DAP another weapon.

(Elwrath's Barley-built swords are breaking down all at once now, but that might be because of the stabbing tips adding extra torque on the build--havent seen a fix for that on here)

The spray adhesive is 3M super 77 I think. I have made a few swords with it. Cheap, easy to apply, dries fast I don't think it's as "sticky" as dap but it works well enough.

Any idea of the durability and longevity of that 3m super 77 adhesive?

3m spray 77 is not the answer. it is fine for a patch or haft padding but stiking it isnt any good.

as far as best practices with weapons? what are you building? normal swords, 30-36 length , .524 kitespar is becoming very common, with solid core fiberglass popular at 28-32 lengths.

4lbs eva common in the "barley" weapons, i havent had any problems in 5 years with that foam. i have wrecked 4 boxes total, all were well within the beaten to a pulp catagory, had i mainbtained the weapon properly the out layer been replaced, probibly would have saved them all.

on top of the 4lbs, many are using either FF cross link poly at 1" thickness, or a combination of volera and blue camp, i strongly prefer the cross poly for longevity.

stab tips, usually a 5/8ths of yoga mat or ensolite. usually dapped, occasional carpet tape. then a strip of tape on the flats to aid in keeping the tip together.


for bats, a 1" square box of 4lbs, 3 layers of volera and skin it in packtape for surface tension.

hope that is what you are looking for.

How long has Elwrath had his Barley swords?


Only reason I'm asking is because I have a pair I specifically bought for pell work. After 2000 strikes I'm looking to replace them. The one I use for practice, however, has lasted me almost 2 years. I had to replace the stabbing tip, but thats because I stab. A lot.

Exactly what I was looking for Bo; I also caught up with Alric. I'm going in on shipping with him, which is nice. I have a huge shopping list and a busy day ahead of me. Thanks for the help!

Peanut of Loderia wrote:How long has Elwrath had his Barley swords?


Only reason I'm asking is because I have a pair I specifically bought for pell work. After 2000 strikes I'm looking to replace them. The one I use for practice, however, has lasted me almost 2 years. I had to replace the stabbing tip, but thats because I stab. A lot.

I wana say hes been using them since okfest 2011?

4 pound foam has made the biggest difference for me in longevity for sure. more so if its a routed box instead of just making an eraidor build.

Stay away from eva on striking surfaces though, other thne a dense eva on a box... the **** worthless. Breaks down too fast and rips apart.

yep, 2lbs eva is **** for striking, tears way too easily.