Well, that sounds like an awful amount of effort to me. Though your dedication to safety is awesome!
I'm a big fan of ultra-lights. Been building them for a few years now and other than punching Tugen in the eye, I've never given a sword related injury. (and, hey. It's Tugen. Seriously, no better person to get punched in the eye, right?)
My materials: Funnoodle, blue camp foam, clear tape, graphite core, something to cut with. Usually a kitchen knife. A roll of grip tape, and a cover.
My setup: First, I cut 3 round disks from the blue foam. I measure them to the size of the noodle. Then, I also cut two very small strips of blue foam and then tape them to the core to prevent rattle and sliding. I also cut small disks enough to fit into the top of the noodle.
My technique: Next step is to cut the core and foam to the size I need. For a short sword, I use 32' core. This accounts for the extra length of the tip and pommel.
I first shave the the base of the noodle and, then tape the noodle to the core right above the built-in grip of a golf shaft using torque wrapping techniques, being sure to leave about an inch of room from the tip of the core to the top of the noodle. Then, I simply stuff the small disks inside the noodle. The top disks get taped to the noodle with just one small piece of tape to keep them in place. I run three strips of the clear tape up and back down the length of the noodle, overlapping each strip by just a small amount. This is sometimes called planking. I make sure not to leave any noodle exposed as that could lead to making the sword degrade faster. The added reenforcement of the tape, combined with torquing the noodle down to the core, keeps the core from pushing up through the foam as quickly. Also the small disks help reduce some of the damage caused by, well, stabbing people a lot. They reduce friction I believe.
The next step is to build my pommel. I eyeball a small enough piece of noodle, cut it, and again torque it to the bottom of the core. I add another small disk, followed by a larger one one.
Add some grip tape and a cover, and swing in glee. Maybe even brandish your new toy in front of you, and in your best Tom Hanks scream, "Look what I have created!"
My swords last between 3-5 months before I blow out the tip or the core. I don't swing nearly as hard as some of the other vets, so that might be why they last that long. 'Course, it could be that I put time and effort in building them as well.
Hope this helps,
Nettle