Reddit mentions of We Sell Mats 48 Sq. Ft. Charcoal Gray 2' x 2' x 3/8" Interlocking Foam Floor Mats

How about this stuff? A bit thicker than a yoga mat. Not free, but not overly expensive if you were building more than one or two bags.

They are sold at walmart/big box home improvement stores as well.

Ooh, I just thought of something else - go to a carpet store and ask if they have any underlay remnants - there should be something that works perfectly for your needs.

I bought 12 of those fairly cheap interlocking floor pads. They aren't as good as the rubbery ones that most gyms have but they are good enough.

http://www.amazon.com/We-Sell-Mats-Anti-Fatigue-Interlocking/dp/B001EJI6CK/ref=sr_1_15?ie=UTF8&qid=1376153406&sr=8-15&keywords=gym+mat

If you're wet blocking and in need of mats you can also go to a big box store and look for foam exercise mats like these I bought a four set ages ago... You can connect and get the shape or size you need. It was much more convenient to pick them up in store and cheaper than the mats I priced online. Mine are holding up great after about 3 years of use (and I knit almost exclusively lace so they get a work out)

I would suggest EVA foam. It is easy to work with and CHEAP. You can often find it at hardware stores as workshop flooring. Harbor Freight sells them in packs of 4 big tiles for $10...which is more than enough to make a large sword. I love Harbor Freight for cheap hardware stuff... check them out if you have one around.

Basically, this stuff;

http://www.amazon.com/We-Sell-Mats-Anti-Fatigue-Interlocking/dp/B001EJI6CK/ref=pd_sxp_grid_i_0_1

It is easy to cut into desired shapes. You will probably want to add some sort of boning for support (wooden dowels, bent coat hangers, whatever). Judging from the Zabuza sword you want to make, you might need more of a mop handle support.

Before painting it, you will want to seal it. This is best done first with heat to melt a lot of the foam cells on the surface closed. I used a cheap heat gun I got for $15... its like an industrial hair dryer. A hair dryer would probably work to if its hot enough at close range. A very quick brush with a blow torch has been used for this purposed. You want to hit it just enough to make it a little shiny... not deform the top. I suggest cutting out a small tile to test with first.

After the melt sealing, I suggest going over it with Modge Podge craft glue (from any hobby shop... Hobby Lobby, Michaels, ect). Once that dries, you can prime and paint!

There is a useful EVA foam tutorial series that you might want to look at,

http://www.youtube.com/watch?v=uXxDfv2NaDY

Best of luck! I'm having a blast working on my DragonCon costume now. I'm doing an armored version of Captain Harlock from the old Galaxy Express animes.

I had this issue as well (neighbors came a-knocking at 10pm to tell me to shut up). I never played a night again but I bought a set of 4 of these. I'm not sure how much they help, but I felt that not only the pedals transferred noise, but hitting the pads on the frame would get transmitted through the legs.

Thanks for this idea! I was trying to figure out what I was gonna do once I brought my squat rack and weights back home. I have a ton of room but I have tile flooring... You think this would work if I doubled up on them? It's foam :- \

Thanks :D Looks good, what did you make it out of? Or was that the foam...? Is it like this foam http://www.amazon.com/We-Sell-Mats-Anti-Fatigue-Interlocking/dp/B001EJI6CK/ref=pd_sxp_grid_i_0_1