I don't know how this completely missed the site's attention but, apparently, we've all been wrong about the Sidious/Palpatine Hero hilt: there is indeed a metal copy. It doesn't say what the background and from who's collection this came from, but Propstore's pretty good about authenticating their wares, so this is a pretty special piece because that means this is the only metal copy. Beyond this, there are no other known metal hilts for Palpatine in RotS. Everything else must've been cast from this piece.
Taken from the Propstore auction page:
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Some quick observation and speculation to how they made this piece: if this is all aluminium, and there are definite seams separating the wrapping to the ergonomic grip, how I would approach making this would be to have the main exposed grip bar alu and the wrapping come from a tube. I would do the basic cut-outs of the exposed grip area underneath, slide that over the bar, and then grind out the ergonomic/organic shapes from there. The brass is cut on the lathe, even the "nipple" endcap. The nipple is angled on one side after it's fastened to the end of the hilt to point down rather than outward. In fact, judging from how off center it is, the piece was likely shaped together with the rest of the hilt. The copper cylinder might just be for decoration but that screw is likely functional in keeping the wrapping and grip together.
I've been wanting to remake my Hero Palpy hilt ever since I made it, but now with this dropping, I may have the actual incentive to try and make it as they might've done for this during production of RotS. Maybe even better, using real metal they tried to replicate the finish in paint here.
I’m not too familiar with Palp’s prop, other than the MR pink one. Is this the famous “black” version that everyone talks about? That is what appears in CW, and is apparently the one in the Arrest Scene?