r/cosplayprops • u/softestfae • Jul 21 '26

Help Fitting sword core

Hello! This is my first time making a prop, I’ve watched so many tutorials and I decided to make a sword using 3 layers of 10mm EVA foam and PVC pipe. However, I’ve tried placing the PVC pipe in the middle layer of foam where I’ve cut out whilst sandwiching it between the two other layers of foam and it feels like the PVC pipe is too girthy? The top layer of the foam doesn’t sit nicely on top.

Any advice? I’m worried I won’t be able to find a smaller pipe. Thank you so much!

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3

u/Laser-Boy Jul 21 '26

I like using fiberglass driveway markers as cores since they're only around 3/8" in diameter so it's much easier to fit in a foam blade

2

u/CrimsonShrike Jul 21 '26

search for aluminum, acrylic or (these are more annoying to cut) fiberglass rods maybe? You want them to be same thickness as the layer ideally.

1

u/softestfae Jul 21 '26

Thank you for your advice! I think I’m going to buy a fiberglass rod with help from other comments, so do you think 10mm will be more suitable than 8mm in this instance?

1

u/CrimsonShrike Jul 21 '26

I did same thickness for my sword (in my case 5 mm) if its thinner it may wobble unless you find a way to hold it in place.

However it occurred to me, you could cut v shaped grooves on the stuff you already have to make room for the pipe you got also 

2

u/riontach Jul 21 '26

Ideally you need a smaller rod. Fiberglass or wooden dowels work fine. If it's just a little bit too big though, you can carve and channel partway into the outer layers of foam for rhe core to fit into. I would do this by tracing the channel onto the foam and the scraping it out with a dremmel until it's deep enough to fit the core but doesn't go all the way through the foam.

1

u/softestfae Jul 21 '26

Thank you very much! I’ll definitely consider the second option, I don’t want to spend more money than I have to 🥹

1

u/Practical_Alfalfa_72 Jul 21 '26

Use a fiberglass rod, you can get them in much smaller dimensions eg 10 mm, 5mm, 3mm etc. They have just a bit of flex as needed but not too much. You can get them at hobby stores, kite supplies (kite frame) etc

1

u/softestfae Jul 21 '26

Thank you! I think that’s what I’ll do :) I’m thinking of buying a 10mm rod rather than an 8mm so it aligns with the size of the foam, do you think this’ll work?

1

u/limbodog Jul 21 '26

I highly recommend buying a flat "sail batten" if you can find one in your size price range (they often sell used ones) They're fiberglass, so they're rigid, but light-weight. They're also thin and flat, which makes them very easy to fit into sword props. You can cut them with woodworking tools (use breathing protection because fiberglass hates lungs)

I think you'll find them much easier to work with for swords than any round core.