i didn't bother writing out instructions (which i can do if people want) but here are photos which show how you can make a very very sturdy crossguard.
you can use the exact same technique for making 90 degree angles at the other end of a weapon also, just make sure you pad everything really well.
if you're just using this technique for a crossguard, you can usually get away with leaving off the electrical tape... this will make the weapon lighter. personally, i like the weight though. any questions, comments, or suggestions?
http://s75.photobucket.com/albums/i293/ ... tructions/
you can see some weapons made with this technique here:
http://s75.photobucket.com/albums/i293/ ... equipment/