We started off by hot gluing pipe foam over 3/4" PVC pipe. Even though the spear is for jabbing only we went with the thicker pipe to reduce whip.
Next we added a couple of layers of foam to the end.
Then for that cool wood grain look we used wood grain contact paper.
Now for the spear head. We glued and taped two layers of the pipe foam extend 6" or so from the end of the pipe. The below picture is only the first layer.
And here is the final product. It came out a bit thicker than I hoped but like I said, safety first.