Easy part – getting the basic dimensions of the foam. Version 1.0 of the sword is still around, so I could easily cut a piece of foam for the main layer. The sheet of foam I have is 100cm length, so there will be some leftover, but I don’t consider it a loss at this point, cause I use those pieces for practicing my cuts.
I’m starting with this:
Foam: 8×100cm EVA foam, 10mm, 100% density:
The first version has a single rod for a core. It is not too flexible, but we decided to try with two to explore the differences. 85cm rods to accommodate the lengthening of the blade, compared to v1.0.
Then comes the width work.
The rod is 9.5mm thick, while the foam is 10mm. It’s kind of fortunate, because the rods need to be tightened together into a single core. This will require a couple of layers of tape, which would also take care of the width discrepancy.
One layer, two layers, double core:
So far so good. Cutting next time.