Scott
Puritan Board Graduate
I made some toy swords with my two boys (7 and 4). Thought I woud share the process for anyone who wanted cheap, durable toys. The boys love them. Anyway, we took some thin PVC pipe (1/2 inch I think) for the length of the sword and handle. Then we cut out two equal pieces of carboard that would form the shape of a guard. Put these together around the pipe at the place you want the guard. Use duct tape to tape them together and attach them to the sword. The kids used colored electrial tape to give the blades and handles color (like magic swords from Lord of the Rings). Anyway, simple, cheap (8' length of pipe was $1.30 or so), and durable. We also made some small hunting daggers, as we had some material left over.