Routed Foam Sword Guide

[Dan of Nightfort]

It seems the full blue foam boxed sword is considered old tech now but the guides still show it and so it still seems standard. Are there any guides around that show the 4# routed core build style?

[Sir Thurat]

What kind of tutorial are you looking for? One on how to route foam? One of on how to apply routed foam? etc.

[warwell]

From the Dag boards - http://www.dagorhir.com/forums/index.php/topic,26058.0.html

YIS,
Rufus of Dragon Coast

[Dan of Nightfort]

Wow, that guide is phenomenal. Thanks for that. If I don't have access to anything but 4# gold gym and blue foam and have a short timeline, should I do the routed 4# box and two layers of blue foam over that? I believe 3 blue foam layers would be a bit too big. The usual 3 blue foam ends up being 2 5/8". This will be 2 1/4" with 4# routed and 2 full blue layers over the blade.

OK, so I have a router. Do I just need the appropriate bit and I can go to town using this tutorial? Maybe this:

http://www.lowes.com/pd_31080-353-85445 ... facetInfo=

[Sir Thurat]

It depends on what core you're using. When using a 1/2" solid fiberglass core, I find that a 4# box still requires 3 layers of blue foam on the blade for it to consistently pass for it. After some break-down time you may find that it hits nicer, but I would recommend 3 layers.

As for routing, that tutorial doesn't show how to route, simply how to use a routed fry. What kind of router do you have? Is it a table router or a hand router? How much experience do you have with routing (anything)?

[Dan of Nightfort]

Sorry, I edited my post after you responded. I have a pretty good amount of experience with a hand router doing woodwork. I will also be working with another person. I don't have a table router. I'm hoping to make a bunch of 3/8 fiberglass shorter swords for nice quality loaners. They will also be great practice for me and the I plan or making my own weapons.

[Sir Thurat]

When I do my routing I use a hand router and a wooden jig I constructed for the guide to run in. As far as measurements, for my blue swords I give a 1/2" allowance on each side, and use a "core box" routing bit to route the channel. You can use a regular guide without a jig, but I find that it moves too much, and any screw-up in the routing makes the fry essentially useless.

Regardless of what you use, be sure that you don't compress the foam when you clamp it down, or you will route deeper than you need, and ruin the channel.

Hope that helps,

-Thurat-

[Dan of Nightfort]

That absolutely helps. I will be getting to work more tomorrow.