Middle Kingdom Boffer Weapon Construction Guidebook

This is the first draft of a weapon contstruction handbook.Please forward any recommendations on changes, or methods of filling in theblanks to knight@galesburg.net

I. Introduction

Welcome to the Middle Kingdom Boffer Weapon ConstructionGuidebook. This guide book hasbeen written for the parent who has not constructed an SCA weapon before.

A. The guide book is divided into two main sections:Single-handed and Two-handed weapons.

This refers to the number of handsthat must be used in wielding the weapon in combat. Single handed weapons may be used in conjunction with ashield or another single handed weapon, usually of the same type (a style knownas "florentine"). Twohanded weapons are usually longer and cannot be used in conjunction with anyother weapon or shield.

B. Determining appropriate length--

1. Single handed weapons may be as long as a) the distance fromthe fingertips, hanging at rest at the side, to the ground, up to b) thedistance from the bottom of the sternum to the ground.

2. Two-handed weapons should not be longer than the height of thecombatant up to 6 feet. Spears inthe Teen division may be 8 feet long.

C. Construction methods--There are several different ways toconstruct boffer weapons. They arespread throughout the guidebook. If the way a particular weapon is constructed does not work well foryou, check the other weapons within the same age group for a method thatdoes. Remember, this is just aguide.

D. If you find a method that creates a legal weapon, and it isnot in this guide book, please share it with us. It may be just the method that will work for someone else.

II. Single Handed Weapons

A. Descriptions

1. Sword: For ourpurposes, a sword is a weapon comprised of a blade and a handle. The handle includes the grip, the hiltand the pommel. The hilt and thepommel may be optional, depending on the division.

2. Mace: A weaponcomprised of a head and a haft. The head is made up of 4 to 6 flanges of a triangular shape with theouter point removed. A macemay also be represented by 4 rounded protuberances at the head.

3. Axe: A weaponcomprised of an axe head and a haft.

4. War Hammer: Aweapon comprised of a large two headed hammer head and a haft.

B. Children's Division

1. Materials: Weapons in this division may be constructed from non-reinforced foam(such as pool noodles), foam pipe insulation, and standard golf tubes as thebase materials. Additionalmaterials include closed cell foam, foam rubber, fiber reinforced strappingtape, and duct tape.

2. Sword

a. Construction materials: foam pipe insulation for 3/4" and1" copper pipes, duct tape.

b. Using the 3/4" insulation, cut a section the desiredlength of the total weapon. Stripone side of the self sealing edge and curl into itself. Strip the other side and seal to theroll. Cut the 1" insulationthe length of the blade, and wrap around the 3/4" roll. Using one layer of duct tape, tape theinsulation together. Reinforce thehandle/blade connection with two or three overlapping strips of duct tape. If the weapon is too "whippy"add layers of tape to the overlapping tape.

c. A basket hilt may be added to this sword by cutting anelongated triangular shape fromclosed cell foam. Cut an "X" into the point and the oppositeend. Push the handle of the swordthrough both "X"s and cover with duct tape.

3. Mace

a. Construction materials: golf tube, 1" foam pipeinsulation, closed cell foam, strapping tape, duct tape.

b. Haft: Cut thegolf tube to the desired weapon length minus 5". Using strapping tape, cover the cut edge, then close bothends of the tube by covering with strapping tape.. Set aside and construct the head.

c. Head: UsingDiagram A, cut six pieces from 1/2" closed cell foam. Cut additional notch from 3 pieces. Stack three pieces together and tape theoutside edge together. Repeat withthe other three pieces. Slide thetaped pieces together through the longer notches. Slide the cut end of the haft into the shorter notch andtape. Cut pipe insulation the lengthof the haft minus 3 or 4" (depending on your child's hand size). Slide theinsulation onto the golf tube against the head. Carefully put one layer of tape over the entire weapon.

C. Youth and Teen Division

1. Materials: Weapons in these divisions may be constructed with Schedule 40 1/2"PVC pipe and end caps (or equivalent size CPVC) or 2 golf tubes (1 inside theother) as a base. Other materialsinclude closed cell foam, foam pipe insulation, foam rubber, strapping tape,and duct tape.

2. Sword

a. This method uses PVC pipe, foam pipe insulation for 3/4"and 1" copper pipes, and duct tape.

b. Blade: Cut PVC pipe the desired length of the total weaponminus 1 1/2". Cut both the3/4" and 1" pipe insulation to the desired blade length. Cut an extra length of 1" pipe insulation. Put the end caps on the pipe and tapewith strapping tape. Cover theentire pipe with strapping tape. Slide the 3/4" insulation onto the PVC, extending it 1 1/2"past the end cap and seal. Openthe 1" insulation and put around the blade. Cut a strip from the extra piece to fit into the space tocomplete the cover. Tape aroundthe blade in 3 or 4 places to hold the two pieces of pipe foam together. Cover the entire weapon with duct tape,being sure not to compress the foam.

c. Grip

1) Handle: Cover with soft tape.

2) Hilt

a) Crossguard – This may be constructed from a golf tube bycutting it to the desired length and then cutting a whole to push the swordthrough it. This will be easier if it is done before the end cap is placed onthe sword.

b) Basket Hilt – Plastice hilts are the best for this age.

3) Pommel

3. Mace

a. Haft

b. Head

4. Axe

a. This method uses PVC pipe, end caps, closed cell foam(1/2"), foam rubber (2"), strapping tape, and duct tape.

b. Haft: Cut the PVCpipe to the desired length of the weapon minus 1 1/2". Put on end caps and tape with strappingtape. Cover the entire pipe withstrapping tape.

c. Head: UsingDiagram B, cut two shapes from the closed cell foam. Cut two strips of closed cell foam the desired length of theentire haft (from tip to handle). Cutaxe head shape from the foam rubber.

d. Construction: Place one haft/head shape on the working surface. Place prepared pipe along the haft(placing end cap 1 1/2" from upper end) and the foam rubber head on theshape. Place second haft/headshape on top. Put one long stripalong side opposite the axe head. Cut second strip to fit on the other side (be sure to put on tip). Carefully cover entire weapon with onelayer of duct tape, making sure not to compress the foam rubber head.

5. War Hammer

a. Haft

b. Head

6. Lanyards

7. Thrusting Tips: Using 1/2"closed cell foam, cut 8 (eight) 11/2" squares. Alternating the direction of thestrapping tape, tape one section at a time to the end of the weapon, beingcareful not to compress the foam. Cut 2 (two) 4"x 1 1/2" sections and 2 (two) 4"x 21/2" sections of closed cell foam and place along the sides of thethrusting tip to create a square (the 1 1/2" sections will be on oppositesides and the edges inside the 2 1/2" sections). Cover loosely with duct tape. Thrusting tips should be a different color than the rest ofthe weapon in order to be more visible.

8. Striking Edges

III. Two-Handed Weapons

A. Descriptions

1. Great Sword

2. Polearms

3. Spears--a spear is an extra long polearm with a thrusting headonly. As such, it is not allowedin the Children's Division, because thrusting is not allowed.

B. Children's Division

1. Great Sword

a. Construction materials: golf tube, closed cell foam, strappingtape, duct tape.

b. Cover the ends of the golf tube with strapping tape. Cut a strip of closed cell foam thedesired length of the blade and wide enough to encircle the golf tube. Carefully cut "V"s the lengthof the blade about 1" apart. Placing the end of golf tube 1 1/2" from the end of the foam, wrapthe foam around the golf tube and tape.

c. Grip

1) Handle: The foam should not cover the last 4 inches of thegolf tube.

2) Hilts

3) Pommel

2. Polearms

a. Haft

b. Head

C. Youth Division

1. Great Sword

a. Blade

b. Grip

1) Handle

2) Hilts

3) Pommel

2. Polearms

a. Construction materials: PVC pipe (1/2"), foam pipeinsulation for 3/4" copper pipe, closed cell foam, strapping tape, ducttape

b. Haft: Cut the PVCpipe to desired length minus 4" for one thrusting tip or 8" forthrusting tip and butt spike. Putend caps on and cover with strapping tape. Cover the entire pipe with strapping tape. Cut the pipe insulation to cover thePVC minus the lower handle. Ifusing a butt spike, cover the last 3" with insulation.

c. Head: Cut the desired blade shape from the closed cell foam,as many pieces as needed to make the blade as least 1 1/2" wide. Make the thrusting tip on the blade end(see thrusting tips above). Laythe blade pieces along the haft just below the thrusting tip. Tape in place. If using the butt spike, make athrusting tip on the handle end. Cover with duct tape.

3. Spear

D. Teen Division

1. Great Sword

a. Blade

b. Grip

1) Handle

2) Hilts

3) Pommel

2. Polearms

a. Haft

b. Head

3. Spears

E. Striking Edges

IV. Shields

A. Shapes

B. Construction Materials

C. Edgings

V. Glossary

Basket hilt

Closed cell foam--a dense type offoam. Foam camping pads are theright thickness and come in 20" x 72" size. It may sometimes be found in 3/4" thickness (used forshipping large machinery)

CPVC--similar to PVC pipe, it isusually a yellowish color. Ithandles temperature changes better than PVC. The wall construction is thinnerso that 3/4" inner diameter CPVC is similar in dimension to 1/2" IDPVC.

Foam rubber--a light foam, used forpillows or floor mats. Comes invarious thicknesses.

Golf tube--a plastic tube used tokeep golf clubs separated in a golf bag. Found in sporting goods stores or sports departments.

Haft--the handle of a weapon.

Head--the striking portion of ahandled weapon, such as an axe or mace. A sword "head" is the blade.

"Mass"--the weight of aweapon. In period a mass weaponwas used for bludgeoning rather than cutting or stabbing, so it was a heavyweapon.

Strapping tape--fiber reinforcedtape often used for mailing packages.

PVC (Schedule 40)--a"plastic" pipe, usually white, used for water piping in homes.

PVC (Schedule 80)--a heavier pipewall construction of PVC. It isheavier and less flexible, thus making it less suitable for weaponconstruction.

Siloflex – a heavy duty pipe.Used in the SCA for armored combat swords.

Shield basket – The coveringof the hand under the shield. This is normally composed bars or a dome toprotect the hand and fingers while gripping the shield.