Stiff Collar Tip Construction

by Hrelgar
Last updated: 1/21/2008


First make a collar out of stiff foam. To make this, I use 2 hole saws, 2 3/4" and 1 1/4" in diameter. I got the foam from Mandrake Armoury and is 1 3/8" in thickness. It's the same type of foam that's used to form the hook on their spear tip kits. I first use the large hole saw to cut out a disk. It ends up being just a tad over 2 1/2" in diameter. I then use the smaller hole saw to cut out the center of the disk. I do it in this order so that I can use the center drill hole from the first cut to center the second cut. I then carve out a chamfer on one side of the disk  using a sanding disk tool. I go slow and sand a little at a time and go around the disk several times to try and keep it smooth and symmetrical.

Photo note: Click on an image to see the photo at full size.


Here is an example of the collars I made.

Follow this link to see the source of this foam.

You also need to make a pool noodle tip. Cut the noodle 4" long or so and round over one end as desired. This can also be made with stacked foam circles using walmart camp pads.


First I wrapped strapping tape completely over the end of the tube. This helps block water from getting into the tip.

A leather disk is required. It can be a small disk over the end of the tube or a large disk covering the collar and the tube. If you go for the small disk (about 1 1/4"+ in diameter), then apply it now.

Then wrap some 3/4" strapping tape around the tube 1" down from the end of the tube. This forms a stop to keep the collar from sliding down with use. I've been increasing the diameter to about 1 1/2" which seems to be enough.
Wrap friction tape completely around the end
Note: I've found that electrical friction tape may be too sticky and can be hard to get the collar aligned right. I'm trying hockey stick tape now and it seems to be a decent compromise.
Now slide on the stiff foam collar. This is a very snug fit and takes a little coaxing to get it on.

Note that the collar will extend a little past the end of the tube by about 3/8". I figure this provides a little extra cushioning to help keep the tube from projecting into the foam tip and degrading it. At least that's the theory anyways.

Now is the time to apply the large leather disk (about 2 1/2" in diameter) if you go with that option. Note that with my testing, using a large leather disk rather than the small leather disk improves the durability of the pool noodle foam. Then completely tape over the collar and then down over the tube with strapping tape. Then VERY tightly wrap around the tube just under the collar. The collar is now locked into place.
Add the foam tip and tape over it lengthwise with strapping tape, extending it down over the tube. Completely cover the tip. Wrap it tighly around the tube just under the collar.
Now wrap strapping tape around the circumference of the foam. I've been doing this with 2 layers to fully support the foam tip.


Now completely cover the tip with yellow duct tape.

Proceed on to the Testing page.

Or go directly to the Conclusions page.

Any questions or suggestions? Feel free to email me at igelkottinus@yahoo.com .