Well, today was another day of progress, but it's the best kind of progress. The kind where your vision starts to come into focus and gets really exciting. Today I crafted the blade in preparation of fiber-glassing the week of thanksgiving or a weekend soon.
Onto the pictures!
Here is the blade, roughly shaped out of EPS, or Expanded PolyStyrene. This was cheap and super lightweight. I used a super dull dremmel sanding head to shave down the EPS, which couldn't support much force for fear of snapping.
Next I covered this in masking tape. This is simply a layer of protection for the EPS as fiberglass resin will eat the EPS. I made sure to cover the whole thing with a solid layer of tape.
Here are the pieces so far. Clockwise from bottom left is the Pommel, the PVC Handle, the Crossguard, The blade (taped up), and the 1/2 in Dowel rod that runs through the sword.
Here is a picture of the Dowel rod sitting in a recess within the PVC recess.
From there the PVC will slide down into the recess. Once all the pieces are in a finished state, it will be put together permanently.
The the cross guard will slide down and it has a recess on the underside for the PVC handle part.
A pic of the recessed underside of the cross guard.

It is very exciting to see something you plan on paper start to resemble your prop in real life!