Roxas and i made ours out of wood so if you want to o that route i can give you some tips but personally i found the wood to be a long and annoying process that and those props are sorta heavy in my opinion so i would suggest maybe going with foamboard bc its cheaper, easier, faster, and you don't have to have any special tools or experience.
but of course there is the con to foamboard that its not as strong as wood but from my experience if you treat your props with respect the durability isn't a factor. Also with more layers comes more strength too.
but ya I don't know if you ever saw rosabella's lightning sword but i made it with foamboard
well i guess if you would like more info on one of those methods just pm me but i know there are other ways just look in the props forum
Upcomming costumes 2010: Joey (yu-gi-oh)?, Leanne (Fire Emblem), Tidus (FFX), Rukia (Bleach), Kasagua (Sengoku Basara), Locke (FFVI)
Conventions 2010: Con Nooga, MTAC, Dragoncon?, AWA