This weekend I took the plunge and started on my costume for Blizzcon 2011, I decided to start with the weapon since I'm not sure how I'm going to create some of the trickier parts of the costume yet.
In the past I have used wood for my weapon props, but as Blizzcon restricts the materials that can be used, I figure I'll give foam a try. There are some great foam based weapon tutorials and a wood weapon this size would be a pain to carry around all day.
I haven't worked out how to do the glowing orb in the blade yet, so expect more questions to follow. :)