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if you want an exact size you're going to have to go to a framebuilder who will take 10-15 measurements of your body to build a custom frame. based on your height and inseam, 52-54 is your off-the-peg size. most companies build in 2cm increments so you aren't going to get any better than that without a custom build
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http://www.directplasticsonline.co.uk/HDPESheet/Natural/8mm/
they have other thicknesses also, but i think 8mm seems a good balance of strength and weight?
you would use a hole saw of both inner and outer diameter, creating 2 pieces, then welding them together, and finally weld that to the mallet head, so it would fit inside for strength
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well i think plastic weld cement will actually chemically melt PVC/ABS to form a molecular bond but i'm not sure if it would have the same effect on polypropelene (which i think those chopping boards are made of). epoxies don't take well to it since it's so soft, so screwing is probably a better plan, seems like a good idea as a material though. check the pound shops for cutting boards :)
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lol@dangeruss...
in other news it looks like the 12:15 ferry will be overrun by polo bikes