The problem i ran into making PVC chucks was the large opening on the ends. They are lighter, but the cord you use is more prone to fraying quicker, and IMO, it swings rather uncomfortably. Thats just an opinion though.
As I said though, I got pretty clever with the PVC pairs i've been constructing. Hopefully, when I get home tonight I can take pics of all my DIY's ive done this past month and upload em to the forum.
I've come to the conclusion that PVC is the ideal pair for freestyle nunchaku. I made some wooden ones, and I love them, but they just dont swing as fast and light as a nice PVC pair.
Customization is wide and easy with PVC as well. Hopefully i'll have some pics tonight.