so, just resheathing the sword is that dangerous? I would expect that someone would be very careful with a blade that sharp, unless the person were very foolish by nature. I have a few "Wallhanger" katanas, and I'm looking to buy a good bokken... any ideas where to look? or if there is a specific wood, I can carve it for myself out of? I don't have any illsions of being a master sword-smith, or anything like that, but I am pretty good at carving wood... also... should I buy a real katana for a dojo (after asking the sensei about what specifications are needed) should I buy the wakazashi, and Tanto as well? and do I need to be looking for Lamellar armor? (that last one's a little goofy, but I'd rather ask it, and look stupid online than not have what I need for training. Also... would my prior training in Go-Ju-Kai help me at all with Iaido?
Actually, resheathing the sword is the most dangerous move in Iaido (to yourself) because you are bringing the sharp edge in to your body.
When you are drawing the sword you are moving the blade away from your body. When you go through your cuts, blocks, and chibari, the blade is at a distance from your body. Resheathing is the only time that you bring the edge back towards you in a way that's close enough for the blade to contact your vital organs.
One expects to be careful, but the difference between success and a horrible mistake is a fraction of an inch. The katana is also a very long blade. To resheath it, one must have the handle extended at an angle that feels a bit awkward. Mistakes can happen because sheathing the sword properly and bringing the sword just inside the sheath in towards one's body can feel like the same move.
One's body size also plays a role, esp. in the beginning. A smaller person with smaller arms may have a more difficult time obtaining proper leverage than a larger person.
As far as a bokken, it's absolutely possible to make one. Katanas are not heavy swords, some weigh less than a kilogram. A beginner student is likely best served by a bokken that was similar in weight. I'm guessing good woods for that would be the lighter hardwoods such as maple, alder, or ash. The martial arts suppliers that advertise here such as centurymartialarts.com and karatedepot.com likely all sell bokkens as well.
As you advance, you may want to have bokkens of different sizes and weights. Many Iaidoka also have heavier bokkens of oak, ironwood, etc. as a way of strengthening the arms.
I wouldn't recommend buying a real katana yet. You actually don't need anything at all to begin training, because your induction in to your training with Sensei will involve going over what you need to buy, what you need to wear, and how to wear it. Your wazakashi and tanto will be pointed out to you then, and you will likely be given recommendations for what sword to buy.
I would hold off on buying a quality katana. Your first sword should be an iaito, and sensei can assist you with purchasing one. On a different note, a quality katana can be upwards of $1,000...there is a tremendous benefit in learning more about the art and the swords so when the time comese to make an investment, you know more about what swords you personally prefer.
I don't know very much about Goju Kai personally. From what I do know, it is a classical style of Japanese karate and generally very disciplined. That will definitely help with Iaido. Also the mental training necessary to learn by watching (somehing I'm terrible at) and learning from kata will be very valuable.