I finally had time to test coating part of the foam blade with casting resin. The worry had been that the foam blade could be easily damaged by light impact, so I wanted to try adding some strength to the surface.
I mixed up a tiny amount of casting resin and painted it onto the "floating" part of Shalamayne's blade. This piece is small enough to work on, and small enough to be replaced if I messed it up. The plastic sets quickly, so the surface isn't perfect, but I think I got the hang of it.
The next step is to sand it smooth, prime and paint. I want to be sure it will look perfect before I apply the same to the main sword blade.
But even given that, the foam does feel much stronger.
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