I used a light-metal Curtain rod as a core. It can carry a lot, yet it is very light not to mention cheap! I made the swords rough shapes in cardboard but slightly smaller so I could cover it with plastic sheet for a better finish. I cut out all and used a whole lot of hot pistol glue (my best friend). I put on some red leather on the handle, sanded some small plastic-cards that made the parry. Added some details to it, and that is pretty much it. I used a metallic (titanium-looking) spray. Next time: prime it properly, use more layers of it and then use a sealer! Then it's going to look a lot better. But I was having to paint it roughly 12 hours before we had to leave to the con, so I am glad it did look a bit like metal at least!
Result:
Reference:
To complete this sword I'll add the dark metal-plate in the base of the sword, a few details along the blade, round off the top and make the handle and parry a bit thicker. When this is done with I will make the fully assembled 6 part "The First Tsurugi" from the Final Fantasy VII: Advent Children movie. That is one hell of a sword to make, challenge accepted.
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