/cgl/ - Cosplay & EGL

Ive got a question for anyone who makes their own props. Im making the Flamberge that Kratos uses from Tales of Symphonia for my GF, and so far its been going pretty smoothly. the blade/handle are formed out of Azak with bondo to round bits out, a bit of wood to help with the hilt and pommel etc. The issue im running into is making the handguard. Ive tried Styrofoam, heavy paper, cardboard, and that green florist foam stuff. Any suggestions on what to do? This is my first time making any type of prop for anything, ive been through the sticky so any aditional help would be appreciated.