Well, I finally planned out my staff and ordered components. Ordered enough to make 4 of them -- figure I'll donate the other three once I get all of 'em to pass weapon inspection.
While I know that no weapons master in their right mind would approve a weapon on its design specs alone, I would appreciate a review of my design spec for any obvious issues.
For the ends, per Traceroo's preference, I've opted to include thrusting ends (even though they're not required nor are staves allowed to thrust), as well as a good bit of overhang. Should make the ends super safe. The design spec is for a 70" staff.
As currently designed the spec is:
Core:
Pipe is 60" length of 3/4" cPVC 400PSI secured to foam with two lengths of double sided carpet tape.
Padding:
2" Wide Thrusting tip -- 3" overhang of noodle (packed with leftover noodle foam) -- 12" of noodle over pipe -- 36" 5/8" wall / 3/4" ID pipe insulation over pipe -- 12" of noodle over pipe -- 3" overhang of noodle (packed with leftover noodle foam) -- 2" Wide Thrusting Tip.
With 4" overhang instead, staff is 72" total vs 70" total.
Diagram below for 70" spec (to scale, 1px = 1/8"):
Key:
Green - Thrusting Tip. 2" length, 4" width (approx)
Orange - Big Boss Fun Noodle. 15" length total, 4" width (approx). 3" overhang.
Brown - Foam Plug (extra material from scrap fun noodle). 3" length (to fill overhang), 3/4" wide.
Beige - 5/8" wall, 3/4" ID pipe insulation. 36" length, 2" total width. This is the 3' grip length.
White - 3/4" cPVC. 60" total length, 3/4" wide (cPVC is measured at OD vs. PVC measured at ID).
Black - Background.
To respec to 72", simply increase the overhang sections each by 1".
I anticipate this design will have a good bit of weight. I consider this desirable in a staff.
Is there anything obvious about this design spec that would give a weapons master cause for concern before I start building?