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I've recently come across the opportunity to buy some squads of the old metal grey knight strike squads on the cheap, and I realized that they all come equipped with force halberds rather than force swords, which is the default under the current codex rules. I was wondering if anyone had any idea of how difficult it would be to either convert the weapons themselves, or remove the halberds and replace them with force sword bits.

Easier to remove the weapons at the back of the gauntlet or hand than at the hilt. In terms of surface area for the bonds, go with the wrist/hand or back of gauntlet/greave.

I've done a few halberd to sword conversions on mine (which are ALL metal GK) to lower the costs of the units - but I stopped playing before 6th ed, and no longer care if they aren't cost effective.

Thanks for the advice. I was thinking of getting some of these : http://i.ebayimg.com/t/40K-Grey-Knights-GK-Nemesis-Force-Swords-Only-Bits-5-S-/00/s/MTIwNFgxNjAw/$T2eC16FHJFoE9nh6n!6FBQjuguJEyQ~~60_57.JPG

for doing the conversions. Would it be a matter of detaching the halberds from the wrist and gluing/greenstuffing these in instead?

The single handers are a simple matter to attach with superglue at the back of hand join (although like most hybrid metal-plastics, you would be best to pin the join and use epoxy adhesive (like a 5 min araldite) - but superglue and Greenstuff will work almost as well.).

The two-hands-on-hilt will be a little problematic - none of the metal GKs in PA have a left arm in a suitable pose to match both hands, so shorten the hilts perhaps? It's not like they ARE two-handed weapons anyway.