Best method for making medium sized spikes for a costume?

I've crashed and burned twice in my attempts to make a costume of this charming gentleman here(http://i33.tinypic.com/sdp7uu.png), and have finally thrown my hands up in 'fgsfds' and contacted a capable seamstress to make it for me.

But, I am having considerable difficulty in figuring out what to use for the twenty six spikes.

I originally used plain posterboard coated in gesso to form surprisingly study spikes, then filled them with foam and fabric remnants before finally covering them with PVC, but they have since been destroyed and it wouldn't be something the seamstress I've commissioned is up to using. Also, I plain just don't want to make all of them again.

I've since been recommended by various friends to possibly use large foam spikes and model rocket noses, but the fragility of foam is a huge DNW to me, as they would be completely destroyed in the event of me doing something as simple as sitting down or falling over. Also, the general availability of firm foam spikes that are not gigantic, flat-tipped, and expensive is rather awful.

Model rocket noses looked very, very promising, until I learned that, while the look like they'd work and are the appropriate length, they commonly have a diameter of an inch with the larger ones being insanely gigantic, made of heavy resins, and being 20+ dollars per nose.

So, really, any ideas about what to use for these spikes would be an absolute godsend. Though, I'm hoping to say within a 50 dollar budget. Hence why I haven't just gone out and gotten myself some silicone and lightweight casting materials.