It would seem to me that 're=enactors' such as yourself Hugh, would be very sensitive as to sharp points and edges.
Much as in the way I could not buy a "non firing replica" gun (unlesss pressed) as a pseudo collector, I prefer an appearrance of functionality.
You were quite correct about the internal weakness of the BK Viking, but, as a non functional repro I su[[ose it might be ok.
So neither criteria were met. although I did make the 3/8 welded bolt tang change and place a hilt from another demo sword on the newly bladed tang.
I enjoy working with metal and wood after 40 years behind a desk and I would feel very badly indeed if you felt I did not listen to you, let alone the safety issues.
Next time, I'll probably use a 1/2' bolt and have my friend teach me to weld.