Boffer Weapon Safety
Materials Tools and Where to Find Them

CORES
PVC
3⁄4” PVC is an excellent basic weapon core for one-handed weapons and spears.
Generally costs about $3 for a single length
Can be found at most hardware stores in 6 to 10 foot lengths
Graphite
Good weapon core for light weapons, slightly more expensive than PVC
More brittle than PVC
Can be found in various forms for about $6 to $10 per sword length
Aluminum
1” or 7/8” Aluminum tubing is a good core for long weapons, particularly polearms (make sure it
is an acceptable core for the game you are attending before building a weapon with an aluminum core)
Can be cut to size with a hacksaw
Costs about $10 for a 6 foot length and can be found at some hardware stores
-most Home Depots do not carry aluminum tubing

TAPE
Duct Tape
Duct tape comes in a variety of colors and sizes
-Gray, black and white are most common
-blue, red, green, brown, teal, purple, silver, camouflage, and other colors are available
-red duct tape signifies claws, try not to use it for your weapon
One average roll will cover several weapons
Gray duct tape can be found in almost all hardware and department stores
One average roll of duct tape costs $4, a large roll is $7 or $8

Kite Tape
Comes in variety of colors, black is the most common
One roll will make at least one long sword
Less durable but lighter than duct tape
Costs about $8/roll and can be found in some hardware stores and hobby shops

FOAM
Open Cell
Pillow cushioning
Can be found for about $5 per scrap chunk, or buy seat cushions and cut to the size you need
Can be found at fabric and craft stores

Pipe Insulation
5/8th inch tube diameter (see picture).

Make sure it fits snugly the core, but not so tight that it doesn’t fit.
Can be found for about $5 for 4 3’ lengths at hardware stores.
-most Home Depots do not carry 5/8” foam.

TOOLS

Hacksaw
Use a hacksaw or the proper specialized saw for cutting cores to the correct length.
Can be found at hardware and department stores for $5 to $15.

Scissors
An old sharp pair will serve well, since they may get “gummy” with tape glue.
Clean scissors after each use with rubbing alcohol to keep them from sticking.
Can be found for about $7 at hardware, craft, and department stores.

Knife
A sharp unserrated knife works well for cutting foam and tape.
Clean and sharpen your knife after each use.
Can be found at hardware, department, outdoor and kitchen stores.

Exacto Knife
A triangular pointed blade will work well for cutting and poking holes in tips
You may need to replace the blade after making a few weapons.
Clean the blades with rubbing alcohol after each use to keep it from sticking in
the weapon tip.
Can be found for about $3 at hardware, craft, and department stores.

Weather Stripping and Double Sided Tape
Double sided tape or weather stripping will make the pipe foam fit more securely
on the core.
Can be found for about $3 at hardware and department stores.

Boffer Weapon Safety
Where to Find What You Need

Thrift Stores
Thrift and second-hand stores are a great place to find costuming. Even though a thrift store is not
a reliable source of costuming, you can find leather belts, odd boots, shirts that will pass as medieval
and all sorts of other things at a great price.
Hardware Stores
This is where you can find weapon-making materials. Make sure that you buy the right types of what
you need. Exacto knives can be found at hardware stores as well.
Craft and Fabric Stores
Your best bet for open cell foam. You can also get Exacto knives at a craft store.
Magic and Costuming Shops
A local store that has supplies for magic tricks and costumes will often have the make up that you may
need to play a race that requires makeup or prosthetics. Party City and other chain stores may have
some things during the Halloween season, but a local store is more likely to have pancake makeup, elf
ears and many other items a LARPer can use.
Department Stores
Department stores such as Walmart and Kmart are likely to have plain sweat shirts and sweat pants
that you won’t mind getting dirty. Tights and Spandex pants can also be found for a reasonable price.
A variety of notebooks, pens, and other items can be found at many of them as well.

Web Sites
There are a number of LARP related web sites that can help you find everything from weapons to
make-up. With a little research you can find finished weapons that fit your personal needs and even
get them delivered to your door step. You can order armor to your specifications and find all of the
trappings you might want for any character.

Boffer Weapon Safety 
Weapon and Shield Specifications

Weapon Guidelines
All weapons have a minimum and maximum length, grip, and blade length requirements. Certain
weapons including Polearms, Axes, and Maces, requires an additonal part called the head. The head is a open
cell foam part of the weapon that represents a striking surface. All weapons must be created with 5/8 inch
wall closed cell foam. Each weapon must have both a thrusting and waylay tip. The thrusting and waylay
tips are used to cap the ends of the weapons. Tips are constructed using open cell foam, approximately 2”
in depth. All surfaces of the weapon must be covered with duct or kite tape. The tape should be in vertical
strips running the length of the blade to avoid compacting the closed cell foam. The parts of a sword are
labeled on the diagram below.

Below is a list of Minimum and Maximum sizing for many types commonly used of weapons.

Shield Specifications
Shields can be constructed out of almost any strong and light material. Thin sheets of corrugated plastic,
metal or wood work well. The total shield size cannot be greater than 531 square inches, and the longest
dimension cannot exceed 36”. Any voids gaps, holes or recesses, will be included in the overall shield area.
The shield must have 5/8 “ thick foam surrounding the edge. No bolts or other protuberances are allowed.

Boffer Weapon Safety 
Test Your Weapons

You can test your weapons by checking for the following:
1. Check the tips for sharp edges, uncovered foam and general softness
2. Check the base of the tip by squeezing firmly to make sure that you cannot feel the core of the weapon
3. Make sure the length of the weapon is soft and not squished or dented
4. The thrusting tip of the weapon should be approximately 2” deep, and should be as wide as the rest of
the weapon.
5. The waylay tip should be at least 1” deep and should be the same width as the rest of the weapon.
6. The closed cell foam should be firmly attached to the core of the weapon and should not slide or twist
when pulled.
7. The closed cell foam should not be visible anywhere on the weapon.
8. Nowhere on the weapon should the weapon core be visible.
9. The weapon must be taped in a lengthwise manner. This reduces the weight of the weapon.
10. The waylay and thrusting tips should be firmly attached to the closed cell foam. They should not come
off when pulled or twisted firmly.
11. The open cell foam should not rattle when the weapon is shaken. If it does, the foam is not fitted
properly on the core.
12. No foreign objects should be put into or attached to the weapon core to balance the weapon.
13. A weapon cannot be designed to “trap” other weapons.
14. All parts of a hilt of any weapon should be made from open or closed cell foam, and should not be sharp
or hard to the touch.
15. The overall weapon length should not be more than the maximum allowed. Allow for weapon tips when
you measure and cut your weapon core.
16. A weapon should not bend even when swung strongly. In particular, check longer weapons for this problem.

Maintenance
A well-made weapon should last several events without much maintenance, but you will want to check
it carefully before and after each event. Store your weapons in a dry cool place, since direct sunlight can
wrinkle or peel the tape. DO NOT lean your weapons on the tips when you store them, and NEVER lean
on the tips.

Your weapon tips will probably have to be replaced more often than the cell foam.