Step One: Prepare the Core, First Layer

This design is for a very strudy and padded glaive. This designs eliminates the need for haft padding (which will wear out) but does require Evalite as a result. If you really can't bring yourself to buying higher quality foam, the single layer area may be done with tube insulation instead. A kind warning, however, mine isn't exactly the prettiest in the world. Unlike most of my designs, this one does require some accuracy in cutting. Otherwise you'll be doing a lot of trimming and filling in gaps. First, DAP the end caps on your pole. Then, envision your glaive. You will have a striking surface, an incidential surface, and some haft padding. Get it in your head what it's going to look like and mark of your handle now. Cut a strip of Evalite as wide as your pole and as long as everything that is not handle, plus, enough to go around the end, as shown in the picture.

Step Two: Inner Sheath

Now, an Evalite "sheath" is made around the sides and back of what you just built.

Step Three: Incidential Padding

Now, you'll add your incidental padding. Figure out how much of your weapon will be the striking surface. Add a foot to a foot and a half. Mark it. Put another layer over the flat side of the side from the mark and up over the end.

Step Four: Final Sheath

Add the final sheath on the glaive, from the mark to the end (just like the last layer.

Step Five: Striking Surface, Finishing Touches

Take a 2" thick piece of Unifoam and cut it as long as you like. It will need to go up and over the end. Attaching this isn't hard, but requires patience. Spray the end of both the Unifoam and the glaive with 3M. Once it's ready, attach. Hold this tightly for a couple minutes to make sure it sticks. Then, spray and attach the rest. Though it may not seem the case, this layer will hold if you attached it correctly. When you add your sock, design it so it compresses the end ever so slightly. If you are terribly worried and don't believe me, put a strip of cloth tape every foot that circles the blade. The end would be done in a radial fashion. Attach a pommel and a sock, wrap any part of the evalite not covered by the sock with cloth tape (so it wears better)... and pat yourself on the back, you've got one hell of a glaive there! ... (Now I just have to figure out why my eyes are always red in these pictures!)