Didn't read all five pages, however, I do have a few tips and pointers for props and masks.
My Ichigo Hollow mask, I made from paper mache and left it very bumpy and broke off some pieces to leave it looking like mid tranformation. Here is a picture of the mask and how it ended up.
Pardon the bad paint job.
I then applied it with spirit gum and added makeup and the contacts and what not.
I didn't make his sword but I do know how. With a dremel or even a nail file, foam core from dollar tree, and adhesive spray or (not recommended) hot glue, you can easily make one. Here is an example of some props I've made. I just made the pieces, glued them together, and fixed up the edges.