Hi tecker.
The end result will look very much like my foam pipe blades.
The foam pipe is very strong. I have some 8" foam pipe and its laying on the floor just behind a work bench. I frequently stand on it and its as strong as steel.
Its very light weight. The skin is about 1/16" thick the foam is about 5/16" thick.
Its also very light. It seem as though your duplicating this pipe.
It makes a very nice blade. I've just tested a 4ft blade in the tunnel made from 6".
I'll be making an 8ft from the 8" dia. pipe.
Here a couple pictures.




I have a few more but I may have posted to many allready.
Jerry