I've had good results rubbing graphite on my resin guns. Looks almost too real. It does rub off with use. I haven't found a clear that doesn't mute it but it's easy to reapply
Links shield was the very first prop I made. My daughter is Zelda crazy(she's 19). The first shield I made I used foam. It's not the strongest but it has lasted several years. A cpl years ago I did make her a wood one for the ren faire. The wood shield is obviously a lot heavier than the foam...
http://m.harborfreight.com/quick-stitch-sewing-awl-91812.html I've always wanted to pick this awl up to try out. It may be of some help. The reviews say the needles need to be sharpened though.
It kinda looks like a sight gauge with a super glue cap. Is there something connected to side of the cylinder. The hole would have a glass tube inside for reading fluid levels.
Joeranger, my daughter was Han Solo at c2e2 and has a pic with you. Besides the transformer she said you were her favorite. She also said you were super nice.