Tiwaz's Pommel building

A brief history on how I fight...typically on any given week I'll fight for at least 6 hours (last week it was closer to 10-12 hours including fighter practice that ran until 10:30pm) The last time (prior to last night) that I built a pommel was probably about 2-3 years ago (I've have to rebuild swords but never had to rebuild a pommel). I tend to hold my swords on the pommel so I needed a pommel that would hold up to the constant stress, I do not like pommels that wiggle on me when I swing.

You will need:
1 Core of your choosing (I use golf clubs because they're $2)
Military Camp foam
Something to cut with (I use a razor for most cuts and a steak knife for shaving)
Something to cut on (obviously I have a green rubber mat I got at Michaels)
Contact Cement (I use DAP)
Something to brush it on with (piece of camp foam, cardboard, etc.)
Tape (I use 3" wide packing tape but any size will work)
Metal ruler
Duct tape, or Cloth tape (Athletic) per your preference

Step 1.

Cut a 3 inch wide strip of military camp foam that will wrap around your core (depending on core size this will be various lengths mine was about 8 inches long, you can always trim extra off). I cut mine so the natural curl of the foam coincides with the way I will be wrapping it around the core. Use your Razor blade to taper one end so glueing will be more manageable.

Step 2.

Apply contact cement to core and the camp foam (the inside curve of the foam as well as the top of the taper you cut out. LET GLUE DRY.

Step 3.

Wrap the foam around the core and over the tapered cut. Get blade out and cut off excess foam. I wrap packing tape around each layer to make sure it stays where i want it. Note the entire layer of foam is approximately the same thickness all the way around and viewed from the bottom would appear to be a circle. (the tapered top end is showing on this picture under the tape)

Step 4.

Cut a small piece of foam to attach to the base of the pommel apply glue to the base of the pommel and the new piece. Wait for glue to dry then connect pieces.

Step 5.

Cut the excess off the base piece so it conforms to the shape of the previously wrapped foam. (note my butt-cap ended up tapered which isn't optimal I just suck and didn't cut it straight)

Step 6.

Cut another 3 inch wide strip like you did before thats long enough to wrap around the current layer of camp foam. Taper one end and apply Glue to the new layer as well as the foam on the core. Let the glue dry. **I wrap my layers so the ends are on opposite sides the 1st layer is on one side, the 2nd layer is on the exact opposite and the 3rd layer is back on the same side where the first layer ended.**

(preview of how layers should line up)

Step 7.

Wrap the new layer of foam over the previous layer covering the butt-cap and wrap in tape to secure and allow it to set.

Step 8.

Cut another butt-cap large enough to cover the new bottom of the pommel , apply glue to both parts. Let glue dry, then attach. Let set then Trim off excess.

Step 9.

Cut a 2 inch wide strip that will wrap around the 2 layers you currently have. Taper the end, apply glue, allow glue to dry then wrap and tape.

Step 10.

Trim the pommel down into a cone shape (I use a serrated steak knife on this stage and only this stage). I leave about a 1/4 inch of foam at the top and about 1/2 inch on bottom untrimmed due to the compression that occurs during the torque wrap. *Note that trimming this down doesn't have to be a precise process.*

(you can if you want attach another butt-cap to the end of this I however do not)

Step 11.

Apply 4 layers of tape Duct or Cloth to the bottom of the pommel first in a + pattern then in a X pattern. Alternatively you can cut out a circle larger than the pommel and use super 77 or spray adhesive to attach it to the bottom.

Step 12.

Starting at the bottom of the pommel torque wrap around the cone. I end my tape about 1 full layer of tape above the top of the cone which allows me to use cloth tape or tennis racket grip or whatever over the end so it doesn't unravel.

Congratulations You're Done!

This is a cross-section of a pommel from a core I snapped. This pommel is roughly 2-3 years old and has never been rebuilt or even re-taped. Most of the lifting on the tape is due to me cutting it apart.