How to Make a LARP Safe Pirate Cutlass
Introduction: How to Make a LARP Safe Pirate Cutlass
In this tutorial I am going to show you how I made this LARP safe pirate cutlass. This same method could be used to make any form of LARP weapon, so feel free to adapt it to your needs! I will walk you through the steps I made to construct this LARP Cutlass and make it safe to use according to the majority of larp guidelines. This particular piece is not being used for combat but for cosplay, but I have made it safe for most conventions and LARPs. The general guidlines to follow that will make a weapon safe for most larps out there are: Ensure there are two inches of foam between the core and the tip of the weapon, and one inch of foam between the end of the core and the end of the pommel. In addition to this, make sure there are 10mm of foam between the core and the striking edge and 5mm between the core and a non striking edge. Some larps will require more foam between the core and the edge, others may not be as strict, however it is always god to err on the side of caution.
Supplies
10mm Carbon Fiber/ Fiberglass Tube, Hot Glue, Aluminium Can, EVA Foam, Craft Foam, Tape, Contact Cement, Foam Clay, Plastidip, Rub and Buff, Acrylic Paint, Leather Strip, Craft Knife, Knife Sharpener, Brushes, Heat Gun, White Gel Pen
Step 1: Making a Safe Rigid Core for the Sword
This is the most complicated individual step of this build, but it is the most important one for a safe final product. It also seems a lot more complicated than it really is.
The main material of this sword is eva foam, which is a great lightweight and durable material for larp/cosplay weapons and armor, however it is very flexible and will not be a very sturdy or rigid weapon as is. In order to make it more rigid and provide strength to the build, a solid core is added in the middle of the sword. This core should be strong and lightweight. The best materials for this are things like carbon fiber and fiberglass. 220
You want a tube for this build so either order from a hobby store in the length you need, or repurpose something like an old golf club, they work very well for this purpose and are much more cost effective. I am using a 50cm carbon fiber tube with a 10mm diameter.
The problem with this core is over time and use as a weapon, the core can slowly cut through the foam and eventually pop through and hurt someone. In order to avoid this, we will add a two inch flexible section to the tip of the rod and a one inch section to the rear of the rod using hot glue. This will allow the softer glue to flex with the foam and prevent it from damaging the foam and breaking through the surface.
Start by marking one inch on a skewer, and using that to press a wad of paper into the tube to function as a stopper. Repeat this for both sides of the tube, then fill the end of the tubes with glue, this will give the glue on the tip a more firm hold and somethign to attach to.
Then using an old aluminium can, cut a rectangle and roll it around the tube using tape to hold its form and tightly shape it, this will form an aluminium tube the same diameter as the external diameter of the carbon fiber tube. Then, slide this tube off of the carbon fiber tube, and using the same technique with the skewer, ensure the tube is two inches over the end, then slowly fill the tube with hot glue, trying to avoid any bubbles. As the hot glue cools, it will contract and form a well in the top of the tube so continue to fill extra glue for a few minutes as the glue settles. You can use a heat gun, as aluminium is conductive, to heat the hot glue and ensure it sinks down to the carbon fiber and bonds to the glue already in the tube. Then, using a scalpel or craft knife, cut the tape off of the aluminium and unroll it to reveal the hot glue core. Repeat this for the other side, for a one inch hot glue core for the pommel of the sword.
Step 2: Assemble Your Template
You can definitely freehand a design on a large sheet of paper/cardboard/straight on the foam if you'd like! If youd like to copy the sword design I have made, I have attached a PDF template to scale, be sure to print it on multiple pages by selecting actual size or poster settings when printing the PDF. Once you have it printed, overlap the sheets of paper so they line up and tape them together. 220