How to Safely Pad a NERO Arrow

Written by Anakin on ArsMagicae.com

This page contains instructions for constructing NERO-safe Arrows, often called “Realie Arrows” because they are shot from a real bow. Most NERO chapters use “Packet bows” which are bent PVC pipe covered with 5/8” pipe foam, which you hold in your hand while throwing an arrow packet.

NERO Boston’s two non-Tyran sub-campaigns, War of Ages and Bloodlines, have approved the use of “Realie Bows” because their Insurance covers it. If you want to bring a “Realie Bow” into another NERO chapter, be sure to check with them first. Most chapters on the East Coast do not allow “Realie Bows.”

NERO approves recurved bows with a thirty-pound draw (or less) as being safe to use. Compound Bows are not allowed because they are anachronistic. Because both War of Ages and Bloodlines have a Tinkering skill, Compound Bows are being considered and tested to determine their safety.

Materials list: Where to buy it:
Arrows with Threaded Inserts (Web Site) or an Archery Store
Fowling Blunts S.A. USA or an Archery Store
X-acto Knife or Utility Knife Art Supply Store or Home Depot
Cap Tape or Foamee ERV Sales or an Art Supply Store
Duct Tape Local Hardware Store, Home Depot
5/8” Pipe Foam Aubuchon Hardware
Open-Cell Foam Home Depot, in Air Conditioning

A Note on Fletching: there are three basic types of fletching (the feathers at the end of an arrow) that you can buy. Shown from top to bottom, they are Fully Feathered, Trim Feathers and Plastic Fletched. (These names may vary depending where you go.) Basically, the more fletching you have an arrow, the better it will fly…and the more expensive it will be. Since padded arrows often break during games, you might want to start with inexpensive arrows.

Note: there is always one feather on the fletching that is a different color. This feather goes on the outside of the bow, away from the grip.

The first step to building a boffer arrow is to ensure your arrows have threaded inserts. This will let you add the fowling blunt head, and will keep the sharp edges of the shaft from tearing the foam.
Next, you need to buy yourself some Fowling Blunts. You do not want to have a pointed arrowhead on your shaft before you pad it. I recommend Bludgeon Product #5708, found here.
As you can see, the bludgeon tip comes with some small spikes, which you will need to remove with a knife. Please use good knife etiquette and cut away from yourself at all times.
You should sand the de-tipped bludgeon.
Now, screw the bludgeon tip onto the arrow.
Next, cut some 1/2" by 2” strips from the roll of Cap Tape. If you can’t use Cap Tape, Foamee held on with duct tape will also work, but it will be heavier.
Peel the backing off the Cap Tape, and roll it onto the arrow.
Make three wraps of cap tape, each about 1/4” to 1/2” apart. This will allow for air pockets, giving your arrow more of a cushion when it impacts.
Wrap the last piece of Cap Tape over the tip of the bludgeon, and measure a piece of 5/8” Pipe Foam against your arrow. The Pipe Foam should overlap the tip of the arrow by at least 1” and the last piece of Cap Tape by at least 3”.
Slice the Pipe Foam at a 45 degree angle about 1” from the end of the foam. This bevel cut will make it easier for you to tape the foam to the arrow.
Check to make sure the foam is at least an inch from the tip of the arrow.
Stuff the gap with a round of foam, so that a little is sticking out over the edge of the foam. Cut a 2”x2” piece of Cap Tape to cover the end.
Apply Cap Tape, and trim to fit.
You will notice a slight bulge in your Cap Tape. (This bulge may not be visible with Foamee.)
Apply a piece of Duct Tape, in a loud color. (Many boffer weapons are made with dark colors, but if you want to find your arrows, make them easy to see.) Smooth the tape by placing it on the foam, and then running your fingers along the curve of the foam. Be sure to leave at least 2” of extra tape after the end of the beveled foam.
Slice the overhanging tape into three or four pieces. Please use good knife etiquette and cut away from yourself.
Attach the strips of tape one at a time, so they overlap onto the arrow shaft. Repeat the past three steps until the 5/8” Pipe Foam is completely covered.
Roll a piece of tape over the overlapping ends of the tape below the foam. This will help the keep your foam from sliding down the shaft of your arrow.
Cut a 2”x2” “Squish Tip” out of Open Cell Foam.
Place a piece of tape over the “Squish Tip,” but do not smooth the tape down.
Slit the Duct Tape where it overlaps the Open Cell Foam, and press the resulting tabs of tape onto the Open Cell Foam. Then smooth down the rest of the tape.
Repeat the last two steps, completely covering the Open Cell Foam.
With a knife, punch holes in the “Squish Tip” to allow it to collapse upon impact.
To help compensate for the weight of the foam arrowhead, add some Cap Tape to the end of your arrow. Be careful not to cover the nock of the arrow (the part that fits onto your bowstring.)

And you’re done!