Be sure that you place glue on both surfaces to be glued and that you let it dry before sticking the parts together. Securely tape the bottom few inches of the foam to the handle. Two or three layers will be necessary. Sew a cloth cover for the sword by making a tube with one end closed. The cover should be tight fitting.
Some people use a stretchy fabric.
Tape the cover to the handle to hold it on. After finishing your sword, stick it between your mattresses for a night, this helps the glue bond and will make your sword last longer. There should be no point on the blade at which the core can be felt. It should not leave bruises, break bones, break noses, or even hurt very much when swung full force. If it is unsafe, you will know.