I did the metal casting panel, and I'd be happy to work with you to help CAST a hilt & pommel in aluminum. If you're not going to draw the weapon, then you can include a short tab at the hilt where the blade would be, and permanently affix the scabbard there.
Fabric or foam should work fine for Goury's armor, because he doesn't have any weird spikey things or gems embedded in the plates.
( guy1656[at]ados.com - replace "[at]" with "@" )