When the kids were little, some one inch thickwall PVC with paint made some mighty fine Star Wars light sabers (unfortunately, these were stout enough to do more damage to their playmates than actual light sabers would have!)
My father made several 'sun swords' (Thundar the Barbarian) when I was a kid out of PVC pipe that were the hit of the neighbourhood.. he put the 'blades' in pipe insulation then wraped it carefully in wide yellow colored electrical tape. It could still hurt or leave a welt if swung hard enough, but the 'damage' was lessened for sure.
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