I was asked by Saki, the owner of the LARP I go to, Gisido, to make a demo since i was planning on making a pole arm for an eventual character and several friends who want to join and have characters with pole arms.
1. These are the general materials I am using, not counting the open cell (couch) foam, and the adhesive I'm using.
2. The maximum size for the weapons of Gisido (for long weapons such as 2 handers, and pole arms) is 60", or 5 feet. The PVC core i'm using is 60" exactly, but I also need to add extra padding and a crush tip to the tip of the weapon, so I cut off 4", giving me a 3" pad on the top, and a 1" on the bottom (this is more than the rules require, but I like me some safety)
3. This is the base foam I assembled, not adhered yet.
4. I used double-sided duct tape (ddt) (in place of an adhesive, I've had weapons and shields last me years from constructing it with the stuff) to get the foam in place, and using a saw cut part of the pool noodle making more of a blade shape. I then used the ddt to put on more closed cell foam on the sides and tip. There is currently about 1.5" of closed cell foam over the top of the PVC. I used normal duct tape to tape the blade edges on more for more stability. Note that I'm using a jewelers saw to shape the foam to my liking.
5. A zoomed out view of the piece as a whole so far. The foam on the end is for safety when swinging the weapon
6. A more finished view of the pommel end of the pole arm. There ended up being about 2" of padding over top of the pommel.
7. A more finished view of the piece, I forgot to add pics of putting open cell foam around the striking surface, so sorry about that. The striped pattern is a personal touch to go right for the throat, so to speak XD, horizontal stripes make an optical illusion, your eye sees the object as shorter.
8. Another view of the pommel post finish.
9. A complete view. Enjoy.