How To: Make a Hard Blade Cover

A hard blade cover is a length of rigid PVC pipe that a fencing blade slides into, held in place by a bungee cord threaded through two drilled holes. You can make one in about ten minutes for a fraction of what a finished cover costs.

Over the past few years the hard cover has become a staple for a lot of fencers. Whether that is to protect blades against baggage handlers who treat burst-rate specifications as a personal challenge, or just to keep shiny metal off a sweaty uniform, we are not entirely sure. Either way, you can buy them from your favorite online store — or, with a little patience, make your own for yourself or for the whole team.

Quick facts

  • A hard blade cover is PVC pipe plus a bungee cord. There is nothing else to it.
  • Epee blades need 3/4” PVC. Foil and saber blades fit 1/2” PVC.
  • Cut each cover to 36”.
  • 200 psi PVC is plenty. You do not need the highest grade tubing.
  • One 10-foot length of pipe yields three covers, with a little waste.

What do you need to make a hard blade cover?

  • PVC pipe — 3/4” for epee, 1/2” for foil and saber. Home improvement stores stock it in 10-foot lengths, which is the cheapest way to buy it and does not ship well, so pick it up locally.
  • A drill — any cordless drill will do.
  • A 1/4” drill bit — this is the size we use for the bungee holes.
  • Bungee cord — one short length per cover.
  • A file — for cleaning up the drilled holes.

How do you make a hard blade cover?

1. Get the right pipe. For epee blades you want 3/4” PVC; for foil and saber you can go down to 1/2”. You do not need the highest grade PVC tubing, so go for the 200 psi version and save a bit.

2. Cut the PVC into 36” lengths. Most home improvement stores sell PVC in 10-foot lengths, so you will be discarding a bit at the end after cutting three covers’ worth.

3. Drill two holes in the pipe. We use a 1/4” bit. These are what the bungee threads through to hold the blade in place.

4. Clean up the holes. Take the file to them. Drilled PVC leaves a burr behind, and a sharp edge will chew through a bungee cord over time.

5. Thread the bungee and you are done. Run the bungee through the holes, and the finished cover will hold a blade securely.

Is it worth making your own?

If you need one cover, buying a finished one is a reasonable call. If you are outfitting a squad, the arithmetic changes quickly: a single 10-foot length of PVC makes three covers, and the drill, bit and file are one-time purchases you will use again in the armory.

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