The Whackerdasher
@whackerdashery.com
Foamfighting and foamsmithing enthusiast.
Working on creating in-depth and up-to-date documentation on crafting standards/techniques and material sourcing for full contact weapons for foamfighting sports: https://wiki.whackerdashery.com
Working on creating in-depth and up-to-date documentation on crafting standards/techniques and material sourcing for full contact weapons for foamfighting sports: https://wiki.whackerdashery.com
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
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
July 5, 2025 at 1:14 AM
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
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.
June 28, 2025 at 12:13 PM
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.
Prototyping a workholding/fixturing rail for foamsmithing.
June 28, 2025 at 12:09 PM
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.
June 19, 2025 at 2:36 PM
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.
June 19, 2025 at 2:33 PM
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.
And everything still fits in the car for taking to the field. This is unacceptable, too much empty space. I might need more shields.
May 26, 2025 at 6:56 PM
And everything still fits in the car for taking to the field. This is unacceptable, too much empty space. I might need more shields.
Close up of the knuckle duster basket hilts on these matched 'sabers'. Fully foam with no rigid supports, just fiberglass tape reinforcement and 3 laminated layers for strength.
May 26, 2025 at 6:56 PM
Close up of the knuckle duster basket hilts on these matched 'sabers'. Fully foam with no rigid supports, just fiberglass tape reinforcement and 3 laminated layers for strength.
Some detail shots of the takedown connection. Strip of tape is for tighter fit. Would need secured with non stretching tape around the seam for use, or permanent epoxy on both ends instead of just one.
May 26, 2025 at 6:56 PM
Some detail shots of the takedown connection. Strip of tape is for tighter fit. Would need secured with non stretching tape around the seam for use, or permanent epoxy on both ends instead of just one.
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.
May 26, 2025 at 6:56 PM
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*
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*
May 1, 2025 at 5:20 PM
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*
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
macuahuitl
April 13, 2025 at 8:22 AM
hey, I know it's 3 am, but
macuahuitl
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
#Foamsmithing
March 22, 2025 at 2:14 AM
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
#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
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
March 21, 2025 at 8:07 PM
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
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
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.
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.
March 17, 2025 at 3:35 AM
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.
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.
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.
March 17, 2025 at 3:31 AM
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.
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.
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.
docs.foamdom.com/materials/co...
Also took measurements of all of the sizes I've tested so far, data in image.
March 17, 2025 at 3:27 AM
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.
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.
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.
March 1, 2025 at 2:17 PM
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.
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...
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...
February 25, 2025 at 1:40 AM
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...
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...
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.
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.
February 24, 2025 at 1:31 AM
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.
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.
- 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.
February 21, 2025 at 2:14 AM
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.
- 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.
February 21, 2025 at 12:15 AM
Image 8: Bond Plate
- brings the foam strips together and applies even pressure
- adjusts via sliding up and down on bolt using channel
- tighten wing nut on bolt to fix in place
- brings the foam strips together and applies even pressure
- adjusts via sliding up and down on bolt using channel
- tighten wing nut on bolt to fix in place
February 20, 2025 at 8:19 PM
Image 8: Bond Plate
- brings the foam strips together and applies even pressure
- adjusts via sliding up and down on bolt using channel
- tighten wing nut on bolt to fix in place
- brings the foam strips together and applies even pressure
- adjusts via sliding up and down on bolt using channel
- tighten wing nut on bolt to fix in place
Image 7: Crossbeam
- 2nd foam strip is threaded between this and ramp
- clamps guide arms in place
- acts as mounting point for bond plate
- bolts stick out of standoffs with springs on them, wingnuts to adjust tightness
- 2nd foam strip is threaded between this and ramp
- clamps guide arms in place
- acts as mounting point for bond plate
- bolts stick out of standoffs with springs on them, wingnuts to adjust tightness
February 20, 2025 at 8:19 PM
Image 7: Crossbeam
- 2nd foam strip is threaded between this and ramp
- clamps guide arms in place
- acts as mounting point for bond plate
- bolts stick out of standoffs with springs on them, wingnuts to adjust tightness
- 2nd foam strip is threaded between this and ramp
- clamps guide arms in place
- acts as mounting point for bond plate
- bolts stick out of standoffs with springs on them, wingnuts to adjust tightness