Constructing the hilt

Build the cross from closed cell foam or similar material.
The closed-cell foam is not stiff enough. Use duct tape to compress the foam into a smaller, denser bundle.
Use a strip of leather to reinforce the closed-cell foam, so that it won't pull away from the blade.
Slide it up from the pommel into position.
Use a wood rasp or file to round the tip of the handle down to 1" diameter.
Take the pipe cap and spread contact cement liberally in the threads. (Concerns have been raised about the long-term safety of this pommel weight. Stay turned for possible modifications.)
Screw the pipe cap onto the pommel of the sword.
Wrap the grip with three layers of duct tape in a spiral pattern with ~1/2" of overlap. This helps even the grip and adds weight to the hilt end of the sword.
Duct tape the cross firmly in place. Cover all of the cross with duct tape to protect it.
Wrap a piece of duct tape around the grip right at the cross to hold the tape that holds the cross.
Wrap a piece of duct tape around the ricasso right at the cross to hold the tape that holds the cross.

Note: Center of Balance: 16.5" from butt