Materials

Hello friends!

This post will be about Dagorhir weapon materials. It is not a construction tutorial but rather about what types of materials and tools you may need and where you can find them. There are a LOT of different things people use so this is not a end all list but will give you a better idea about what kinds of things you can use. The tech has evolved so far from when I started that some things listed here are definitely old and some a lot better but all of it CAN be used to build a safe weapon for our game.

Cores

When choosing a core for your new weapon, there are a few things you need to consider: length and weight of the weapon, its flexibility, and its durability. When dealing with something that is longer and/or is meant to pack a higher punch, flexibility becomes a main concern. The MOA states that no swung weapon may flex over 45* and no green only weapon may flex over 90*. So you're going to want something that can handle most of the weight being focus on the striking end without flexing out. The flip side, is that flexibility will directly affect how hard a weapon hits. A very stiff core will transfer more force to the target and it may end up failing. IE. ive seen fiberglass hockey sticks as cores and those weapons hurt and never passed.

Durability should be a pretty straight forward concept. Pvc is old tech and it will make a safe weapon, but it has the highest chance of breaking, and that does happen. ( it also flexes the most) Solid fiberglass has the least chance and the thicker the more durable...but refer to the flexibility point. Hollow fiberglass falls right in middle but again mostly depends on wall thickness, diameter, and length.

The last point is weight. Again straightforward concept but some people like heavier weapons that are more realistic and some prefer lighter ones to gain a more competitive advantage.

Here is a simple diagram that show some of the available options and their effective lengths, it’s not perfect but is fairly accurate.

Here are some links for some of the different types of cores:

round fiberglass bulk (4-20 per bundle) - http://www.electric-horse-fence.com/products/posts/fiberglass-posts#5/8-inch

http://www.kencove.com/fence/Fiberglass+Posts_detail_F12-4SG.php

http://www.electric-horse-fence.com/horse/products/posts/fiberglass-posts

Round Fiberglass (singles) - http://www.mgs4u.com/fiberglass-tube-rod.htm

Square Fiberglass (bundles)- http://fiberglass-rods-bars.com/bars.htm#.U8xeFfldV0w, or http://acetal-rod-sheet.com/fiberglass-frp-bar-stock.htm

kitespar- .524 OD or .602 OD

http://www.goodwinds.com/merch/list.shtml?cat=fiberglass.tubularfiberglass, good winds also has regular round fiberglass.

https://www.acpsales.com/OnlineStore.php?cat=5321

https://goodwinds.com/

bandshoppe pole (flag pole) - 8'

http://www.bandshoppe.com/catalog/productDetail.do?p=Fiberglass_Flag_Poles

5'-8'- http://www.swbandproducts.com/store/flexible-fiberglass-flag-poles.html

https://www.zoro.com/dynaform-rd-tube-isofr-gry-1-odx18-in-wall-10-ft-871010/i/G0516914/?category=8048

https://www.dxengineering.com/search/brand/dx-engineering/product-line/dx-engineering-fiberglass-tubing?autoview=SKU

Foams

There are a lot of different types of foams that are used for different applications but the two most important types are Open cell which is usually used for arrows and is old tech for stab points, and Closed cell is what we use for almost everything else.

Note* MOST closed cell foams, regardless of name are actually different variants or brands of polyethylene,

When it comes to closed cell foams, there are a few things to keep in mind including: density, tear resistance, and weight

The MOA USED to state that the minimum width of a striking surface had to be 3”. This was due to the fact that the only materials people used were blue foam and pvc. You put 3 layers of blue on the pvc core and it was almost guaranteed to pass…. an exact recipe for making a safe weapon.

Now, with the advancing tech, we don't need to hit the 3” mark anymore but the weapon still has to pass a safety check. 3” is a good number to base your weapon off but if you are using higher tech it can end up smaller and feel better, but it gets fairly complicated….just make sure build it up and double check along the way.

For a sword, the most commonly used thickness of closed cell foam is ½”. It is also possible to buy 1” or thicker to save you time layering foam, but that process requires extra steps to prevent extra stress at the tip of the weapon which can cause a blowout. This is normally done with a routing table but if you don't have access or don’t want to risk it, go with ½” foam.

The most common densities are 2# and 4#. 4# is sometimes used on the first layer that adheres to the core in order to increase the durability and longevity of the weapon. 2# is the generally accepted density for higher quality foams and can be used by itself. Blue foam falls somewhere between 2-3# but it is sometimes inconsistent.

When it comes to shields, people mostly use 3” 1.2#, polyethylene . You could decrease the thickness and up the density to avoid your shield becoming too flexible as well tho.

In the construction of most PD gear, you will want a foam in which the cells are smaller and more compact in order to achieve a smoother surface. Most of the higher quality foams that you can buy don't require a “skin” to be applied for this, but when that is necessary, you can either buy one of those in an 1/8th” thickness or get a specific type of foam that is available at most walmarts and joans called Foamies or “Fun Foam”

Here are some different types of closed cell:

Ozark trails Camp Mat, commonly referred to ask “Blue Foam” - https://www.walmart.com/ip/Ozark-Trial-Camping-Pad-Blue/16783660?wmlspartner=wlpa&selectedSellerId=0&adid=22222222227010668902&wl0=&wl1=g&wl2=c&wl3=94350392777&wl4=pla-211570912817&wl5=9014904&wl6=&wl7=&wl8=&wl9=pla&wl10=8175035&wl11=online&wl12=16783660&wl13=&veh=sem

2# Volara- http://www.foambymail.com/VA/volara-foam.html

2# evalite from mcmaster- part # 86095K24

2# Microcell- http://www.foamforyou.com/minicell_foam.htm

2# Polyethylene Foam Roll - http://www.foambymail.com/VA/polyethylene-foam-roll.html

4#-http://foambyconbuilt.com/order_foam.htm#FCB2605G%20%20Crossed%20Link,%20Closed%20Cell,%20Vinyl%20Acetate,%204%20Lb%20Foam,%20Gray

Foamies- https://www.walmart.com/ip/Foam-Roll/24634197

https://www.alibaba.com/product-detail/Cross-linked-polyethylene-foam-manufacturer_60116180860.html

http://www.mwmaterialsworld.com/en/cross-linked-polyethylene-foam.html

Tape

There a few accepted types of tape used in constructions each with their own purposes.

Strapping is used to secure stabbing tips because the fibers allow it to compress in one direction but not other whicis important so that it doesn't rip off, but compresses correctly.

Cloth tape is used mostly for handles but can be used to secure pieces where there is not a lot of force being applied to the weapon.

Duct can be used for some things but it is best not to put it anywhere near the striking surface. It could however be used on the flat edge of a sword to further secure the layers of foam together.

Tyvek can be used as a sort of skin because it allows air flow while letting moisture out, but not in. This is interesting because when a weapon gets wet, it affects how the foam compresses and can cause it to fail or become damaged. Note* Tyvek is a brand name, this is a tape used for securing insulation on buildings. It can also help with durability.

Dap Contact Cement

This is Dap, use it for everything but make sure its the original and not the gel: https://www.lowes.com/pd/DAP-Weldwood-Original-Contact-Cement/3033216?cm_mmc=SCE_PLA-_-Paint-_-Glue-_-3033216:DAP&CAWELAID=&kpid=3033216&CAGPSPN=pla&store_code=2852&k_clickID=2f7bcb6a-25fe-42e6-823b-0bb4c183401c

Here is a tutorial for a basic blue sword: http://archive.li/vnVn9

If you have any questions feel free to ask them on the facebook page at https://www.facebook.com/groups/53807528807/ and keep in mind that this is not an end all list. Tech is always changing as new materials and techniques are discovered!

Thanks all,

Squire Loki Madog

Admin of Rivendell

Sergeant of Wargar