I used the expanding foam when I built my sons WoW swords. I filled the blade baout 1/2-3/4 of the way, inserted a 1/2" dowel, and then put a little foam in the handle and put that on the end of the dowel sticking out of the blade. I was using 90# cardstock. It didn't affect the color in the least and made it sturdy enough for the kids to fight with. The only drawback I saw was that after the foam expanded, it stuck to the sides of the model and then shrunk a little, causing some of the sword to "cave in". As far as non-expanding foam, experiment with it first, build something small and see what it does (it might shrink and distort the model like the expanding foam did).
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