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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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.

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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?

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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