Hey, thanks for the shout out! I did make a scratch-built Luke ROTJ a few years back out of stuff from the hardware store as a sort of exercise. But it was the shared stunt version, not the hero. There was another guy who did a hardware version of the Luke ROTJ hero and I can't recall his board name, but it was pretty awesome.
My Luke was made from washers and aluminum pipe mostly. It would be highly impractical for dueling. You can see it in this photo along with a couple of my other scratch-built sabers. These are 90% aluminum pipe, washers, and PVC. I have no machining abilities, so everything was hand cut and polished using a dremel, hacksaw, and needle files. I look at these things now and marvel at the patience I had back then. I could never do something like that now. The fin on the Dooku was hand cut from 1/4" aluminum sheeting.
http://www.ryannagata.com/files/gimgs/32_sabers.jpg