This site has become unusable. Every other post is just some flasher that isn't brave enough to flash people in person, or some fetishist out to yum every yuck they can find, and no amount of blocking and reporting does anything to keep them out of my feed. Find me elsewhere if you need me.

🆕 The Wordsmith #swordscomic

104" boffer spear, 18.5 oz, 1.5 oz of that is the built-up handle. Built on the new High Modulus (390) 14\*10 spec. The test of 230 Modulus for this spec/length/application had too much flex and is getting cut down. Only added 1.5 oz over the previous build. (next to 8.5' glaive) #Foamsmithing

It also acts as a mount for these glue-up clamps that I use to keep foam half-tubes together when gluing them down to the core and while the adhesive sets. They work without the rail, but the rails let me keep multiple aligned, which is helpful for longer weapons, like 7 foot long javelins.

The Whackerdasher@whackerdashery.com · last yr.

Prototyping a workholding/fixturing rail for foamsmithing.

Prototyping a workholding/fixturing rail for foamsmithing.

One can never have enough shields. New bucklers and shoulder shields, built on coroplast, edging stabilized by strapping tape. 2.2# PE facing, 2# XLPE edging. The rectangular buckler came out to 17 Oz.

Been binging prototyping of lightweight and inexpensive 3D printed handles for boffer weapons. Have them down to 1.2 oz per 6" out of ABS. My new TPU arrives soon, hoping to achieve an approximation of an over mold with that over the ABS, or use varioshore TPU for variable stiffness throughout.

Flex testing carbon fiber. Aside from the first two, all of the other weapons are built on tubes of varying thickness with a 2mm wall thickness and 230 GPa modulus (which determines the strength/stiffness of the carbon fiber). youtu.be/zmDg0kZB_Zw Testing higher stiffness/modulus in next order.

Carbon Fiber Flex Testing - May 2025

YouTube video by The Whackerdashery

youtu.be

Finished a new batch of boffers over the weekend all (other than some repairs of old kit) built on the custom carbon. Tested flex on the extreme ranges, turns out we need to dial back some length recommendations and get some beefier tubes for the big stuff. More in replies.

Latest carbon order finally arrived, so I'm all stocked up for Sword Knight Boot Camp. Just under the line for tariffs taking effect, too. Supplier got hit with a surprise retroactive upcharge of $100 on the shipment from the freight cost (not tariffs) going up thanks to impending tariffs. *sigh*

hey, I know it's 3 am, but macuahuitl

One of my favorite methods of covering a shield, as it requires no sewing machine. Some carpet tape around the edge, line the cover up, tack it down taut, then cut off any fabric past the tape. Unstick it, then lay it down tight, pleating as needed, and cover with a durable duct tape. #Foamsmithing

Out with the old, in with the new. Foamdom is now The Whackerdashery and the docs site has been renamed to Whackipedia. www.whackerdashery.com wiki.whackerdashery.com The old domain will still get you to the site until the registration expires near the end of this year. #Foamsmithing #LARP

@bsky.app reporting seems to be broken, today.

Managed a sub-16oz 6' 6" javelin with one of the 14mm carbon cores. 2# XLPE with 4# biscuits on both ends. NBR foundation, open cell point. 14mm*10mm carbon core (polished, unpainted, 3k twill finish). Spear-level flex, handles one handed well, flies very straight, super easy to use.

Took the new shield to an event after getting it finished up, and I now have a new favorite shield design. Looks "ok", but I know I can do a better tape layup next time. Wasn't originally supposed to be responsible for the cover on this one, so it's just some scrap fabric while I'm test driving.

The Whackerdasher@whackerdashery.com · 2y ago

Testing a new design for boffer punch shields. Bent and split/splayed PVC, 1/4" wide zip tie woven between splayed ends and 3 holes in coroplast in a figure 8. Coroplast is 2 perpendicular layers from 18x24 yard signs. Will still be layering foam and filling voids with adhesive.

Put together a write up on ordering custom carbon fiber from suppliers. You can always use this information with other suppliers than the one I've vetted, but your mileage may vary. docs.foamdom.com/materials/co... Also took measurements of all of the sizes I've tested so far, data in image.

Testing a new design for boffer punch shields. Bent and split/splayed PVC, 1/4" wide zip tie woven between splayed ends and 3 holes in coroplast in a figure 8. Coroplast is 2 perpendicular layers from 18x24 yard signs. Will still be layering foam and filling voids with adhesive.

Too wiped after getting this put together to clean up and get nice pictures, but the strip-welder WOOOOORKS! Finding out that I need to make the tubes oversize and then trim them afterwards if I want clean faces, but this is already doing pretty well for a trial run. Now I need another heat gun...

The Whackerdasher@whackerdashery.com · 2y ago

Modeling Complete, at least, for the dimensions I need to model. - Will just be securing the heat gun with stiff wire, threaded through holes on those braces. - Won't matter if it rotates and the handle goes to the side. - Elongated the ramp to protect the foam from getting heated early.

In Carbon Fiber News: Just received and distributed the first 16mm*2m batch from the supplier. The tubes looked great, were well under flex tolerances, and went so fast at $35 each that I had to place another order within a day of them arriving. More details and supplier link in replies.

Modeling Complete, at least, for the dimensions I need to model. - Will just be securing the heat gun with stiff wire, threaded through holes on those braces. - Won't matter if it rotates and the handle goes to the side. - Elongated the ramp to protect the foam from getting heated early.

The Whackerdasher@whackerdashery.com · 2y ago

Finally got far enough with the CAD model that I can start sharing. Additions: - Guide arms to make sure each strip stays aligned - Guide plate above the channel on the "ramp" - Makes sure the two strips are pressed together as you pull the carriage down the trough More info in replies.

tfw when you accidental dragon motif in the tool for fusing foam strips with heat #foamsmithing

The Whackerdasher@whackerdashery.com · 2y ago

Finally got far enough with the CAD model that I can start sharing. Additions: - Guide arms to make sure each strip stays aligned - Guide plate above the channel on the "ramp" - Makes sure the two strips are pressed together as you pull the carriage down the trough More info in replies.

Finally got far enough with the CAD model that I can start sharing. Additions: - Guide arms to make sure each strip stays aligned - Guide plate above the channel on the "ramp" - Makes sure the two strips are pressed together as you pull the carriage down the trough More info in replies.

The Whackerdasher@whackerdashery.com · 2y ago

Prototyping a tool for heat bonding strips of foam. Quite jank at the moment, but works quite well already. Functions like a zipper pull. Made with scrap wood, a drill, and a jigsaw. Those screw heads on the bottom keep it in the channel. Now I can go to CAD. Needed upgrades in replies.

The voices keep circling me back to what feels like an unhinged idea, but I really like it for practicality: Foam-padded gambeson. Instead of many layers of fabric, it would be just two, with strips of 1/8" foam between the stitches. Considering doing similar with thicker foam for a kidney belt.

Realization: I don't need variable channel depth, rather an adjustable guide for pushing the upper strip down into the channel. If I make the channel 2.5" deep, I can make 2.5" thick strips.

The Whackerdasher@whackerdashery.com · 2y ago

Changes for next design: - Longer - Removable walls for channel - Adjust wall height w/ stacked layers - Bottom wall acts as guide, set to width of strip - Other walls act as rails for sled - Walls stack via alignment pins - Guide plates for sled - Better mounting for heat gun

Prototyping a tool for heat bonding strips of foam. Quite jank at the moment, but works quite well already. Functions like a zipper pull. Made with scrap wood, a drill, and a jigsaw. Those screw heads on the bottom keep it in the channel. Now I can go to CAD. Needed upgrades in replies.

Not often I have the time to knock out 2 articles in one day, anymore. Here's one on applying tape wraps. Still have to get images to go with it, and write a section for anchoring and stabilizing guards, but this is a good stopping point for today. docs.foamdom.com/build-techni...

Some articles are easy to write. Some are...less so. Still need to eventually populate this one with images, but the writing portion is at least done: docs.foamdom.com/build-techni... Covers general adhesive use basic contact cements, spray adhesives, hot glue, epoxy, and common surface pairings.

Adhering Materials | Foamdom Docs

Techniques and advice for making things stick to other things.

docs.foamdom.com

TFW you want your adhesives to fully cure in less than a week, not be noticeably offgassing for another week in your weapon, not be spillable or randomly spoil from the lid not being perfectly sealed, and not be at risk of getting collecting debris because it's in an open can.