Step One: Preparation and Edge Shaping

Start by penny ending a single fiberglass rod that is no longer than 2'. Leave a couple inches at the bottom for your pommel, then mark where you want your grip to be with a pencil. Cut 2 pieces of 1/2" Evalite. The only required specifications are that the minimum width on this piece must be .835 inches. The reason for this is if you do it thinner than this, the weapon will fail on the basis of less than 3" width on the flats. (Since the weapon will be under 12 oz. on completion). You will also need to take a small notch out at the top to accomodate the penny end. An important note, exaggerate the shape of the weapon. Make your thinnest parts more thin and your thicker parts more thick than you'll want them to actually look. If you want a crossguard, feel free to add one in this piece. The crossguard as shown on this sword is too small to be functional. After you've got it cut, DAP these thin edges onto the blade. This isn't as hard as it looks - if the edges are not exactly opposite of each other, it won't hurt the end design.

Step Two: Add Flats

In this step, you'll need to cut two flats from 1/2" Evalite. They should be the exact same size and shape as the current assembly. Be careful, the blade is currently very fragile with only the thin edge to hold it onto the fiberglass. After you've got them cut, DAP them on!

Step Three: Add a Stabbing Tip

Cut two pieces of Evalite to cap then end of the weapon. You'll need to ensure they are at least 2" long. After adding the outer layer in a future step, this will ensure that you've got the 3" minimum required for a semi-circular tip. Attach these to the tip with DAP. While it's drying, cut a piece of Unifoam in a semicircular shape (or square if you prefer safety and don't mind the odd shape). The peak of the Unifoam should make the Unifoam at least 2" high. You may need to thin the Unifoam a bit so it's not wider than the blade depending on how you cut it. Once you've got the Unifoam cut correctly, DAP it on. If you do not want the stabbing tip, skip the Unifoam step.

Step Four: Prepare for Outer Layer

This entire step can be skipped if you did not add a stabbing tip. At this point, the stabbing tip has a strong tendency to bend off to either side. The duct tape is being used to harden this portion of the blade so it will not do this as badly. I'd suggest 2-3 wraps of duct tape that covers a small portion of the Unifoam and a small portion of the initial Evalite piece (and of course everything in between). Follow this up by covering the duct tape completely with cloth tape. (Remember, DAP won't stick to duct tape alone!)

Step Five: Attach Outer Layer & Finish

Cut a layer 1.5" thick and as long as the outer surface of your blade. Attach with DAP. The thinnest flat of your blade will now be 3" and the stabbing tip must be at least 3" wide as well. Add a sock, finish your handle, and add a pommel. You've now completed a Hobbit's Short Sword!