Actually, it might work out like that. I haven't tried layering yet. I just enjoy the pepakura process, and swords won't be that hard to build. I'm slowly adding the correct measurements so everything is the right size in real life. I've already created a greatsword based off a buddy's file. Check out the picture.
And here is a picture of my wife holding the greatsword. This tends to give people a realistic feel of what I want from all the weapons I create. The wood layering sounds interesting, but I think I'll stick to pepakura. Thanks for the comments!