Acceptable weapon materials include
For Core
1.Pvc or cpvc pipe
2.Fiber Glass KiteSpar
3.Graphite(Old golf clubs)
4.LIght Aluminum pipe FOR 2 handed swords, polearms and staffs only
5.Fishing rods can work in a pinch as well, they just need a little more prep work.
For Padding
1. 5/8" wall pipe insulation
2. two layers of 3/8" pipe insulation
3. 5/8" thickness of Camp pad/activity pad for Shields. I would recommend NOT using this for melee weapons, just shields
4. Open Cell foam, JO-Ann's sells 2" green foam by the foot. This can be used for axe/mace/polearm heads, thrusting tips, or to widen out a blade, like making a Falchion/Kukri design.
5. In a pinch Pool Noodles can work as padding, if using them for swords its usually good to tape up the length you're using and then remove the tape to get rid of the outer film, this makes the noodle softer.
For Covering
1.Duct tape of the threaded variety, more plastic versions can get hard in the cold and can make sharp edges if not smoothed out when put on a weapon. Plus be aware that red tape means the weapon is a claw and white tape means the weapon is magical.
2.Spray on and painted on types of liquid rubber(Tool Dip) can also be used.
3.Kite Tape can also be used but does not weather very well.
4.Nylons IE, panty hose, can also be used to cover weapons, they are less durable and can get covered in briars and other plant hitchhikers when playing in the woods.
5.Sewn Cloth covers, these need to not be weird colors/patterns, No plaid swords plz.
I probably missed a few but I hope this gives you a few options.
If you have any questions let me know,
Will K.