Well, I bit the bullet and had a go! With the exception of the hilt, I printed everything out on sticker paper and laid things out onto black foamcore. I almost messed up and put ALL of the stickers down onto the foamcore. There are some pieces that are meant to be two sides to a single piece of foamcore... I'm glad I caught myself. They have a nice system of using thumb tacks to line up the printouts on both sides of the foamcore. The whole build took a little over an hour to complete. I skipped the edging that I could have put around the blade. The black foamcore looks OK enough for me, and I could only imagine the stickers not adhering to the sides too well and being more trouble than they are worth.
So, without further ado, here are a couple photos:
From end to end, the whole thing is a little over 3' I think.
My printouts were rather dark, and some of the great details on the hilt are lost. I am pretty sure I'll make at least one more sword (using one of the alternate blade styles) and I'll try to fix the print brightness for that. I also think it would be fun to shorten the hilt a bit and chop the blade down to short sword length. I might take the whole thing and scale it down 70% for my kids!