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Padding the blade edge
- Cut a piece of 1/2" high-impact foam, 3/4"-7/8" wide for the
sword edge. You can either cut two pieces that extend the length of the blade
or one piece long enough to go all the way from the cross, around the tip and
back down to the cross (on the sword edge).
It is better to cut these pieces too long, because the foam should not
be under tension when it is over the blade.
- Apply spray adhesive to the edge of the blade from cross to tip on both
edges.
- Place the high-impact foam so that the 1/2" side is against the wood. The
foam should stand out 3/4" from the sword blade. Run the foam all
the way to the tip. Run the foam around the tip, applying as
little tension as possible. Run the foam down the other side to
the cross and cut off any excess.
- Wrap a piece of masking tape once around the blade and foam in two
or three places to help hold the foam until the adhesive
cures.
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