Okay, I built my prototype loaner sword out of PVC and blue foam using Caretaker's DAPless method (doublesided duct tape) (sorry isk, had the DS duct and no money to try the Rhino, but I will when I can) If it passes Weapon's check, I'm going to try and make a butt load of these for Loaners, and maybe some small round punch shields.
The catch' is, it was quick, and odorless which means I can build them in the house, sitting on the couch watching the 13th warrior' or 'a knights tale'. He he I'm in weapon's making heaven without a headache afterward.
Praise be to Barathor!
Konradr