I would be so disappointed if we didn't get to hang out! I will stalk you D:< Hahahano...
I'm trying to figure out something like that myself. To be completely honest, I'm thinking of just using posterboard, thickening it up with bondo or something lightweight, and weathering it for my sword. Something tells me that won't work for you. Ummm.... I wish I could help? I'm researching some cosplay prop blogs for my costumes, I'll let you know if I find anything.
Expanding foam is G-R-E-A-T for staffs. It's what I'm using for my Merril's. I've never thought about using it for swords though.
Working On: Sailor Moon ◈ Sailor Moon R ◈ 0%
Planned: Morrigan ◈ Darkstalkers
Conventions 2012: Taste of Animethon ◈ CCEE ◈ Animethon
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