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I've built a whip as part of a conversion, so it is a very long, thin piece. I considered a core of wire, but it just wasn't practical/within my ability to get the look I wanted with a wire core.

Now I've got a piece I'm happy with the look of, but probably isn't strong enough, long term. So, does anyone have any tips, beyond using the mini to support it, which will happen, to try and make it stronger/stiffer? Was thinking perhaps some thing like varnish or PVA painted on, but interested to hear what others have tried or succeeded with.

I doubt pva or varnish would strengthen it. A core structural material (e.g. Wire) really is best.

fortunately though when green stuff breaks it usually does so cleanly so can be super glued back together.

Can't think acrylic (?) varnish or pva would be much less flexible.

To be honest, I'm with Wtnind. If you can't get a wire in there, the flexibility of unsupported GS is probably the best option to prevent breaking, compared to other, more brittle options (bend in the wind, grasshopper); even if the GS whip is still pretty fragile.

Any reason you couldn't use a shaped piece of wire without putty?

Best way to harden it is by making hulk mad