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I could post some new pictures of my gunblade. I have used the aluminum-tape on mine but I haven't done anything on it in a long time. The engraving, painting of the gun part, covering the handle in black leather and the chain with the Grieversymbol on it is the things I haven't done yet!
Have you by any means the chance of get the blade done in wood I would rather choose that than layer of layer of layer of posterboard. I had to use a sander to get the shape out of the rough piece, though I liked the result the workspace I used was covered in a layer of paperdust which were a b*tch to clean up. I think it took about 3-4 vaccumings befor it was gone! And that is NOT a joke...
A idea I got when i looked at your gunblade were if you could get a good handle of a toy sword a good idea would be to cut of the gun's handle and cut the sword handle and use some plumber's epoxy to attach it to the gun and then sand down the excess. I think the nerf maverick would be a good base actually just cut the handle of and reattach it about 45°up towards the back. But that may be too big if the gunblade is going to be used by a smaller person. I have no clue how old or big you are but the maverick is a big gun even in my hands and I'm 187 cm = 6' 1.6"...
Sorry for the extremly long comment! But I got to many ideas at once. Hope I were to any help!