If you've got kids who love pretend sword fighting, you know the problem. Regular toy swords break after a few good battles, and more durable options like sticks result in tears and bruises.
As a young teenager obsessed with swashbuckling movies, I figured out a better solution I could use to duel with my friends: DIY PVC pipe swords wrapped in foam. Fast forward a few decades, and I recently pulled out the old designs and made improvements for my own kids.
These swords are wrapped in thick insulation, so you can actually make contact without serious injuries. They’re also durable enough to survive dozens of backyard battles, and they're simple enough to build in an afternoon. Plus, the whole family can get involved in making them.
Watch the video above to see the build process and our kids testing them out, then follow the detailed instructions below to make your own.
Here's everything you'll need to build two swords. All of this can be found at your local hardware store:
Tools:
Before you start gluing anything, you'll need to cut your PVC pipe into the right lengths. Here's what you need for each sword:
Mark your measurements clearly with a marker before cutting. A PVC pipe cutter makes cleaner cuts than a hacksaw, but either tool works fine.
Pro tip: Let the kids help with measuring and marking. It's a good chance to practice measurement skills, and they'll be more invested in the project if they're involved from the start.
Once all your pieces are cut, it's time to assemble the sword. This is where the cross fitting comes in – it creates the guard that separates the blade from the handle.
Here's the assembly order:
Important: PVC cement sets quickly, so work efficiently once you start gluing. Make sure pieces are pushed in all the way before the cement sets. You only get one shot at this, so double-check alignment before the glue dries.
This is the step that transforms a hard PVC pipe into a safe sword. The foam insulation padding is what allows kids to actually make contact during their battles without getting hurt.
Take your foam pipe insulation and slide it over the blade portion of the sword. The insulation should cover the entire 2.5-foot blade section and project an inch or so from the end.
Once the foam is in place, wrap it with duct tape to hold everything secure. Start at the base where the foam meets the cross guard and spiral the tape up the length of the blade.
Creative option: Use different colored duct tape to customize each sword. We've made some with silver tape for a classic sword look, and others with bright colors for lightsaber-style battles.
Once the glue is fully cured, your swords are ready for action. We strongly recommend kids wear safety glasses and helmets during sword fights, even with the foam padding. The foam prevents serious injuries, but an accidental poke to the eye is still possible.
These swords have held up incredibly well for us, but it is possible for the cross guard piece to break if hit too hard. If you have older kids, you might consider using a single straight piece of PVC without the cross fitting to avoid this. It won’t look as much like a sword, but it will be really strong.
Now get outside and let the epic battles begin! Whether your kids are into medieval knights, Star Wars lightsaber duels, or just general swashbuckling, these foam-padded swords will get them outside and fuel their imagination.
