7/30/2019 Eryndor Pvc Javelins

1/1

3/4" (outer diameter) Schedule 40 PVC

Design Key:

Blue Camping Foam

1/2" EV ALite

2" High Density Open Cell

Yellow Fabric Cover

Duct Tape

3/4"

3'7"

1

Product Notes:The mindset for this design is to build anextremely well-padded spear. The result will be ahefty (20 -22 ounces), large-headed javelin thatlooks ugly butflies very well and has exceptionaldurability.

It is very important thatthe open cell used in thisdesign is high density, as poor quality open cellwill resultin a failed javelin.

If desired, a thin-walled, larger diameter PVC corecan be us ed as a s ubstitute for the recommendedcore.

Products Used in the Tutorial :1. High Density Open Cell2. 1/2" thick EV ALite3. Ducttape

4. Hockey Tape5. DAP ContactCement6. 3/4" Schedule 40 PV C7. Yellow Fabric8. Blue Camping Foam

Tu tor ial Note s :

The left image is the s ide view of the J avelin,while the right image is the front view of theJavelin (as though its about to hityou in the eye).

E ryndor Pres ents: J avelin Design 351 - Quick, Cheap, Durable

Cre ated by : AthronLas t Updated: 7-14-2006Co mments: athron@ dagorhir.comThis weapon is designed to meet the s afetyspecifications per RW C XXI .

Approx. Cost of Weapon:

$4.50 - 6.00

90 minutesApprox. Time to Complete Weapon:

Difficulty:

for a generaly simple design thathas one finishingsep that is exceedingly difficultand requires adeveloped foamsmithing "touch" to execute properly

for one javelin

7

Take apiece of "schedule 40 PVCand cutitdownto between 3 ft. 7inches to 3ft. 10inches (any

longer weightMAY become anissue). Cap bothends with DuctTape wraps.

2 Take a 5" x 20" strip of bluecamping foam. Dap both s ides of the

foam, then spiral wrap itself flushagainst one end of the P VC. T his is howyou build up the base of the striking surface.The finished surfac e are a of the cylindricalwrap should be about 3.5" inches in diameter.

3 C ut T WO 3. 5" c irc le s of bluefoam and ONE 3.5" circle of Eva lite (theycan also be cut into an Octagon shape ifmaking a circle is too tricky). DAP thepieces together so thatthe E valite issandwiched in the middle.

3.5" 3.5"

3.5"

5"

1.

5"

1.75"

4.5" 4.5"

4"

4"

2"

4"

4DAP thefoamsandwichfrom Step 3onto thefoam baseyou built inStep 2.

6 C enterthe open cell to thetop of the javelinhead and DAP itinto place. If youhave open cellfoams of differentdensities, the moredense foam shouldbe adheredCLOSE R to theweapon core (thebottom).

7 This is the most complicated step, readcarefully. Rightnow, your javelin head is safe, butmuch too wobbly. To fix this, you will create asupport wrap around the head. Take a 4" x13.5" piece of blue foam and DAP it 2 inches ontothe open cell and 2 inches on the closed cellfoam. The key is to "wrench" (see Green arrows)the foam support wrap tightly around the head tocompress the open cell itcovers, do not be afraidto pull pretty hard. The "seams" of the blue foamsupport wrap will meet, so be sure to DAP theedges as well. Make sure the DAP is set well,and then use duct tape to cover the sea m of thesupportwrap, itwill wantto peel away otherwise.

5 C ut T WO 2" thic k pie ce s of highdensity open cell foam (computer packingfoam or Unifoam, for example) into 4.5"circles (or octagons). DAP the two opencell pieces together (use Spray Adhesive ifyou have itava ilable, its superior to DAPfor this application).

3.5"

1.

5"

38"

Making the Head: Steps 1-7

8 C ut a piece of 4.5" x 38" blue foam(thelength of remainingexposed core). DAP andwrap ita ll the way downthe shaft be sure to letthe blue foam overlap itselfa little bit. While it doesn'tlook quite as sexy as aperfect cylinder, the foamis less likely to separateand create permanentgaps in the shaft (anothercommon reason for JavelinFailure). As soon as youDAP the wrap together,duct tape the seamtogether as well itwillhelp keep the foam inplace as the DAP sets allthe way. Alternatively, youcan use pipe insulation tocover the haft, if you wish.

9 C uttwo 1.75" circles(or octagons) ofblue foam. DAPthem togetherthen DAP ittothe bottom of thePVC (for yourpommel).

Making the Shaft & Pommel: Steps 8-10

Finishing Touches: Steps 11-13

Once the foam sets, youcan trim off the edge tomake it more circular.

2.7

104" x 6blue DAP flushend oJavecompom

11 T ak e a 14 " s qua re of y ellowfabric. Put a small square of ducttape onall four corners. Center the yellow foamover the top of the Javelin head, and thenpull the four corners down onto the headand use the small pieces of ducttape tohelp hold itin place.

12 Wrapthe head in duct

tape. Don'toverdo it, if youwrap TOO manytimes, you couldmake the headtoo heavy. Next,wrap the pommelin ducttape -bottom first, thensides. Lookclosely atthediagram to seehow far to wrap.

14"

13 F oulengths of ducentirely cover longwise. Thiwork better thwrapping" ducaround the shachapter symbohead of the Jayou don'thavesymbol, the ELifeTree worksnicely)