I took a coupling piece for the inch and a half pvc I was going to use and wrapped in sand paper to give a curve to the inside of the guards so they would fit nicely against the couplings in the final assembly
For the main shaft, I used inch and a half pvc, 2 couplings, a large wooden dowel, and 2 endplugs, one of the endplugs was sanded down to fit inside of the coupling and was used on the handle end.
The wooden dowel fits perfectly inside of the recess in the encaps and gives the entire Keyblade rigidity.
I made the handle length just right so that the guards would mount evenly on the couplings when assembled
Once I test fitted the Handle onto the dowel, I cut the piece of pvc for the shaft to the length I needed, taking the end plug into consideration. After that I drilled a hole all the way through both couplings so I could run a wooden dowel through for the attachment of the hand guards, taking care to make sure my holes were drilled straight and parallel .
I struggled a while with how to do the ornamental blue part where the handle meets the key shaft, I finally took a 1 1/4" plastic sink tailpiece and fit it into the end of the coupling. The lg wooden dowel fit perfectly inside of it too, then I shaped the conical part with bondo and spot putty. I then could slide the 1 1/2" key shaft perfectly over the sink tailpiece.
I cut the "key" part out of Sintra after hand drawing a pattern and cut a groove the right length in the end of the shaft to hold the Sintra in place with the help of some epoxy, I put the endplug in and filled in the joint and irregularities with spot putty and sanded it smooth for painting "stainless steel" silver
Everything was assembled temporarily to make sure all was good before painting
I really didn't weigh as much as I expected, It could easily be carried around a theme park or convention all day.
My next write up with be my Predator bio mask with dreads, and then my Iron Man arc reactor !