In the case of my forearms conditioning, are you refereing to strength or or bone strength and pain tolerance? Im not so worried about pain tolerance but my bone breaking is a worry.
A little bit of both, really.
Dallyon, or "forging" in Taekwon-Do is to toughen and strengthen our attacking and blocking tools. The stereotypical aspect of this is the use of the
dallyon joo (forging post, or makiwara in Japanese) but also includes things such as knocking exercises, which is what I do in the mornings. Basically, one knocks their forearms together. This results in increasing one's pain tolerance by toughening the forearms. Ultimately, forging will result in greater bone density.
Your statement that you're "not so worried about pain tolerance but [your] bonebreaking" should be looked at in light of your next statement:
Example, Last night I was playing with my 4 year old daughter. I wanted to try lower block, and she loves playing the "punch,front kick" game with me.(fun game, usually leads to them tackling me and i tickle the poo out of them) Well i had her stand in striking range and told her ok, front kick me as hard as you can. Now to put my self in the proper height i got on my knees so she could reach my vital areas.
First time around she feinted a punch and kicked me in the stomach. So as we proceed, i start using the lower block as i was shown. Every time i threw it and it connected, it felt like i was "smashing" (impacting hard) on her leg, it hurt the bone it impacted on in my arm, tho it did deflect the kicks and sometimes threw her off balance. If it hurt my arm while doing it on a 4 year olds kicks, it will break it on a full power adults kick wont it? At this point i think i may be doing it wrong.
I would say that if you're bone hurts considerably from blocking a kick from a 4 year old you might want to do some forearm conditioning. Start slow with light knocking and gradually build up reps and force over time. Do not rush things. Your forearms will bruise and there will be some tenderness at first. Make sure after you're done doing the knocking exercises you rub your forearms. Eventually, they will stop bruising and simply redden for a while and then return to normal. Make sure you remember to tighten the muscles of your forearms as you strike. This will enable the muscles to form a barrier around the bone so it shouldn't hurt (as much) when executing a strong block. I can't emphasize the importance of being able to move your body from a nice, relaxed, flexible state (during the preparation/wind up of the block) to being as hard as iron (at the moment of impact) and then back to relaxed again, and not just in blocking but in striking and kicking, too. The flexibility and relaxation of the body allows you to develop a high degree of speed, and the rigidity at the moment of impact will increase the damage done to the opponent.
If pain from blocking continues to be a problem you may want to consider seeing a doctor just to be on the safe side and rule out any sort of problem like a calcium deficiency.
You mentioned that you were heavy set and so dodging is tough for you. Heavier people do tend to be able to take a hit, but when facing a proficient opponent I don't recommend it. My instructor is shorter even than me (I'm 5'6") but I don't know many people who can generate more power than him. Work on dodging and think of blocking as an added bonus attack.
Pax,
Chris