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I'm not sure if the guy is around anymore, but there's a gentleman who created a site www.saberology.com and all of his sabers were led. He'd found some company that would create his polycarbonate...

Name: William Lowther
Age: 26
Occupation: Shift Leader, Game Crazy/student
Location: Redlands, CA
Alias: Kyaen
Force Affiliation: Jedi

"You're father wanted you to have this when you were old...

Hey, pardon my ignorance... but how would I straighten that tubing?

"You're father wanted you to have this when you were old enough, but you're uncle wouldn't allow it..." -Obi Wan Kenobi