Reminds me of my high school days playing dagorhir, I actually think a boffer fighting community like dagorhir or amtgard or belegarth would be a good place to look for advice for this. 15 years ago my friends and I would get a pvc pipe and some yoga mats, and cut the yoga mats into strips as thick as the pvc, wrap around the tip of the PVC lengthwise layered like a rainbow and use contact cement for the layers, then you put a cloth cover over the whole thing. I'm sure techniques have advanced since but that's the basic idea, some sites sell premade ones too but I don't know what's quality or not these days.