I suggest you ...

Spearheads/Halberd Heads to mount on your Staffs

How about you change the moulds to the Murten and Spear so they mount on your Wooden Staff? I mean, if you adjust the mould to be the rectangular-ish fit of the staff, and add a drop ridge at the open end of your "heads", they would be easily and safely mountable on the wooden staff, you wouldn't have to change a lot of moulds or worry about the other things! Calimacil foam holds well enough on its own, so all heads would be coreless and therefore stab-safe too!

This way, you could make a lot more variations in halberd heads and spear heads and the sorts, it would really open it up to make smaller, cheaper molds and probably help make them get accepted by more larps!

For instance, there is not a single LARP in the netherlands that currently allows the Calimacil Spearhead or Halberd Head because it has to be mounted on wood and such... Tried my way around that but it's not working.

Here's a drawing to hopefully help illustrate my point.
http://puu.sh/bZbfc/8eabb59d3d.jpg

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