(pretending that I didn't completely forget about this)
My sword is quite similar to Stuart's - we went to Home Depot and bought a giant piece of that pink 2" thick insulation foam together and got them to cut it in half in the store (meanwhile having to awkwardly explain just why we needed almost six feet of insulation foam when we were clearly not making home repairs).
Unfortunately, Black Gold Saw's sword (what a tongue twister) features an entire edge that is serrated, so I had to measure and sketch out every zig and zag along the way.
|The top bit ended up being nixed and enlarged later|
In order to get the hilt to fit snugly into the sword, I cut a rectangular strip down the middle of the sword so that I could insert the PVC pipe. I remade the top part of the sword out of leftover foam (made it larger), so I just cut a hole through that and stuck the PVC pipe all the way through.
|Terrible quality picture is terrible|
Add paper mache, and voila!
Finally, spray paint/acrylic paint it until it looks the way you want it to, then seal it with Mod Podge (but get matte, not glossy...I accidentally used glossy and my sword was much shinier than it needed to be).
The handle was made with Delight air-dry paperclay , and I sculpted the skull on top with stone clay.
The finished product: