Hey all

First off, is there another good spot for foam weapon crafting discussions? Cross game stuff is fine, but another subreddit or forum specifically about foam weapon crafting?

Also, before we start, this would be my first foam weapon craft, though I'm no stranger to other crafting. I have watched a bunch of videos, read a lot of guides, I've use gorg stuff as loaners so I know what quality feels like. Ive made a list of materials and steps and techniques I feel pretty confident with. But I do have a few questions, and treat me like someone who knows nothing, I'm here to learn.

The hilt:. I've seen people do a quick wrap or tennis grips. I've also seen a bunch of cord/twine wraps, but everyone is vauge about what cord/twine they're using, they don't mention material or diameter. I've also seen it done several ways. Can someone clue me in the advantages and disadvantages of:
Different materials? I see similar stuff availabke in jute, hemp, nylon, poly, linen. Some are tougher, some are natural, are any too tough for the hands? Wear too quickly? Feel better?
Different sizes? I think 3mm looked good but I see down to one and up to like 6. Any thoughts there besides obviously the thickness/weight, but like grip-ibility/comfort?
Under/over layers? I've seen people wrap leather or foam around the rod then cord over that, Ive seen people do a top layer of leather or cloth, any thoughts on doing an under layer, an over layer, both, neither, is it material dependant, etc?

The shape of the blade:
The majority of the blades I've seen are simple gorg like rectangles covered by cloth. I did see a few people shape the foam to be more sword shaped, but those ended up being latex or plastidipped. Obviously I'd have to keep a good minimum padding, but any other reasons not to do this? Should I use softer outer layer foam if the edge is a bit thinner because of shaping? Is it near impossible to cover a shaped blade with cloth or is it the same process or....?

Cloth covering - Ive heard trigger cloth is the best if you want to see it. I've never sewed before but I'm willing to learn, but I'd be doing it by hand not with a machine. The guides just say sew, are there specific threads I should use , specific needles, should I look up any specific type of sewing technique? Anything different if I try and do a shaped blade instead of rectangle?

For counter weighting, I saw several good methods. However, I noticed the rods I was looking at have as an optional accessory some rubberized rod caps a bit over an inch long. I was thinking of just putting whatever weight I needed in the hilt end rod cap before gluing it on, then pommeling over it, seems like a decent plan, right? (Obviously doing test weighting with tape first to get the weight right)

Also, I've heard the best grips are ovalish in the direction of the blade, to help you know the orientation. Do most people ignore this and keep it circular, or do you foam wrap then shape the hilt, or how do you best do this?

Thanks for all the guidance, I'm leaning hard on your experiences