Step One: Preparation and Layer One

This design is for a simple "barrel" mace. The term is borrowed from Nolan's Barrel Mace Design. Practically the same design, but mine is made to be harder. In the more recent days of Dagorhir, it seems more respect has been given to weapons that hit with a fair amount of force. That said, this will end up being 3 layers. It's just as padded as a regular blue sword and just as safe. The other thing I'll do is show you how to put a stabbing tip on, if you so desire. This design is intended to make a simple blue mace. This design should not be used for red maces as the leverage on such a swing will likely need more than 3 layers. 4 would probably be fine, but I haven't tested this. Step one, attach 2 PVC end caps to your pipe, using DAP while still quite wet. Then cut a piece of blue foam long enough to wrap completely around your PVC. Attach with DAP. Attach the circle of foam on the end of the pipe. (Gotta love my shoddy craftsmanship here...)

Step Two: Head Wrap

Now figure out how big your head (striking surface) will be. Make a full wrap this big (and to cover the foam circle on top), attach. Then one more foam circle. This will leave you with what is pictured.

Step Three: Final Layer

I f'd up and did not get a picture of the next step, so it's only explained in words. Final layer of your striking surface is another wrap, big enough to cover the previous wrap and the circle. You do NOT need to attach another foam circle. This is incidential padding and two layers on a blue is plenty. If you want to add a stabbing tip --- this is the step you'd do it in. Before adding the final layer, cut out a piece of open cell foam in a rough circle. It should be 1-2" in width, at least 2.5" in length to prevent eye gouges. (Ovals are fine, but ignorant weapons checkers and players will act like something is wrong if it's not a full circle 2.5".) Attach this using Spray 90, or lots of DAP while it's still wet. The open cell may overhang what you've built. No big deal - this is pretty standard on my designs. Make the final blue wrap now. It should be long enough to cover the previous wrap, foam circle, and an inch or so of the open cell. If you have overhang on the open cell, this layer need to be tight. You will compress the foam so the final wrap, from a side view, should look like a perfect straight line. This will make your stabbing tip extremely secure. Again, another simple quick weapon from Al'Kazar's Forge. And keep in mind this is the perfect weapon for newbies or for a quick draw. As there is no "flat" you're guaranteed a proper swing.