These are the recipes I use when making long (48") and short (36") swords.

Total Length 48"
Handle 11"
Tip Pad 3"
Pommel Pad 2"
Pommel 3"
Blade 30"
Total Pad 36"
PVC Length 43"

Total Length 36"
Tip Pad 3"
Pommel Pad 2"
Pommel 3"
Handle 6"
Blade 22"
Total Pad 30"
PVC Length 31"

Quick Steps:
1. Cut the 1/2" PVC to the specified length.
2. Cap each end with PVC slip cap. If the cap won't go on, sand the end until it will.
3. Cut the pool noodle blade, and slide it onto the PVC core.
4. Make three to five 1" sloping cuts in the blade near the handle.
5. Do a torque-wrapping using the cuts you just made. Regular packing tape is fine for this.
6. Cut out six 2.5" diameter circles from camp pad.
7. Stack 3 camp pad circles on top of the blade and tape them on. Use two 2' strips of strong tape like Scotch Extreme Tape.
8. Cut 2.5" of pool noodle. Cut this in half to create the extra tip pad. Affix it with a 2' strip of strong tape. Align it so that the tape overlaps multiple pieces of tape.
9. If you are using pipe insulation to pad the handle, you should slide that on now. Place a strip of packing tape on its seam before sliding it on. That should prevent it from splitting.
10. Cut the 3" pommel from pool noodle, and slide it onto the PVC core.
11. If you're not using pipe insulation, torque-wrap the pommel like you did the blade.
12. Stack 3 camp pad circles on top of the pommel and affix with two 10" strips of strong tape.
13. If you are using 2 mm craft foam to pad the handle, put that on now using vinyl electrical tape.

The details of sewing the covers are not included here. In short, you sew a pair of tubes and slide them onto the blade and pommel. You can use shoe laces or other cord to keep the covers on, or you can just use vinyl electrical tape.

Supply Costs

    * Pool Noodle $2.18
    * Strapping Tape (30 yd @ $5.13) $0.35 for 2 yd
    * PVC Pipe (10' @ $1.67) $0.56 for 1/3 (10' provides 2 long and 1 short, or 2 short and 1 long)
    * PVC Slip Caps $0.59 for 2
    * Eletrical Tape $2.07 /10 $0.21
    * 2 mm Craft Foam $0.54 for 9" x 12"
    * Camp Pad $13.11 /30 $0.44
    * Black Sport Nylon (3 yd @ $17.18) $1.72 for 0.3 yard
    * Heavy Duty Thread $1.83 /10 $0.18
    * Estimated Total $6.77