I know my Roxas made her Keyblade out of duct tape and.. ah.. I forget what else. But it was a sort of hard paper that she bought at Michaels. It turned out really nicely, too. So you don't always need to make it out of wood. It'll be a lot lighter, too. And trust me, carrying around something made out of wood gets tiring easily. I carried my Chakrams around at Sakuracon all three days, and they were made out of wood.
But it turns out we're gonna have a mini group this year of Kingdom Hearts! Not too big. A Sora, Riku, Namine, and a Kairi. Plus us as Axel and Roxas. We might do a skit, or something. But we might save that for Akicon, too. XD