I don't know the answer to your question, but I will say, #1, I always wanted to do that show, #2 I have done a lot of pirate shows, and yes, swords that "clink" make for wonderful fights. I have some homemade metal swords, they are easy to make and very dull :)

 My homemade sword are just 1" and 1 1/4" flat stock steel.  I take one piece about 4" long and cut a slot in the center, this become the hilt. Take another piece however long I want sword, say 36", slide hilt on, weld in place. Handle is just duct tape wrapped over flat stock. Cut some sort of  dull point in business end.  "Blade" is spray painted silver. They clank well. Even dull, they can certainly do damage too, and need to be treated like the weapon they are. I like handles that are long enough you can grip with both hands, esp when kids are handling them.

Edited by Majicwrench - 9/03/11 at 12:59am