The "horse shoe" around the bird's head looks like mold flash to me that wasn't cleaned up.
No, I was referring to the little "terminal" wire end by the tail that wraps around the entire medallion to the other round terminal end. There's a tiny bit "stripped" from the gold one and the resin one on opposite sides (almost like whatever they used there was installed in reverse on one of them if they came from the same mold (don't know if that's something added on the metal ones or part of the casting itself as on the gold one there's some residue pool at around the bass that could have been glue or solder or whatever then coated or sprayed accordingly...I'm not sure how that part was assembled. The closeup of the "menora" on my gold one shows similar "grey" matter here and there in the photo that looks like the same stuff securing the braid, whether some dull looking solder or other adhesive or whatever).
In an earlier post you asked if the braid had been a separate part on mine. Mine is a resin casting from the ILM mold and had the braid as part of the casting. Fans who are producing metal copies are likely adding the braid as a separate process, since the fine detail may be hard to achieve in a metal casting - and a real braid will just look cleaner anyway. Any production castings would have had the braid as part of the casting to simplify the process.
So was the original Imam screen version using an soldered wire braid added after casting or is it part of the mold? I thought it was the former in all on-screen versions of that one. According to RM's message to me (discussing a slight issue with a spot on the braid area on the replacement/second "Raven Bar" medallion he sent me), that version has its wire wrapped around it before plating, not part of the mold itself. Again, I don't know what they did on the "Raven Bar" medallion for the on-screen version for sure, but I take it RM tried to make it the same way the original "hero" version was, at least according to the description.
Now whether further castings for stunt use or cast gifts were made differently, I guess they certainly could be. I thought that picture posted earlier of an example of a cast gift looked kind of like a painted resin version (i.e. almost too perfect on the surface to be gold plating and looks like my painted Resin version except for the tail feather area once again).
Did the cast members get resin versions or metal versions or were some of both made for various cast members or is this an unknown?
Knowing what I do about film productions, I would imagine that there was likely only one real metal head piece ever made (the hero or close-up) and any others (back-ups, stunts, etc..) would have been resin castings. I don't know this for certain, but productions companies prefer to spend as little money as possible - especially for unproven new films (which Indiana Jones was back then!). They aren't going to lavish money on anything unless it's absolutely necessary; and even then, they will try to go as cheap as they can.
That's interesting, but it does beg the question about two of the medallions sold at auction, one with the red opaque jewel that claimed in the description to be the on-screen version the way I read it (I can't see how it was when no version on-screen I could see had a red opaque jewel in it, not the close-ups anyway, which I mentioned earlier in the thread that I think the guy who bought it was possibly auctioned something under false pretenses at like some exorbitant amount) and the one I posted a comparison picture of next to mine that also seems to share the same (or extremely similar) tail feather mold that sold for $60K at auction and claimed to be a cast member gift as well.
I've also read what implied Elstree versions had acrylic jewels in them while the "hero" version had a swarovski crystal (which aren't quite as "rare" as some descriptions would have us believe as they regularly appear in bulk on places like eBay for no more than a dollar or two each in quantity, but as you say, "cheap as they can" ?). My "ILM" gold one and the RM "Raven Bar" one look identical in terms of the crystal in them and how it behaves with a camera flash and held up to the light, but I can't be sure it's a real crystal. The "Acme" version actually sparkles noticeably more in photos and reflects light better from lamp-lit viewing angles, but looking closely I think it may have a partial mirror back (which is an option with or without normally on that version) still installed around the edges (and clear in the center) which would cause the light to reflect and refract more. The plastic resin one has a jewel that looks like cheap plastic (not very clear and nothing resembling a crystal-like sparkle to it). Of course, the Bam Box version has an opaque RED jewel in it. The 'German' "reel art" one (I bought used for the Landron base rather than the medallion) has an amber gem, but I have no idea what it's made out of. I'd guess acrylic by the looks of it.
Frankly, I'm rather fascinated by all these variations on the medallion (I guess I wouldn't own six if I weren't and I'm still thinking about the "German" RM one as it looks much nicer than the "reel art" one front and back, but seeing it wasn't in the movie, one can only guess what it might have looked like for sure. Given Toht's hand, I'd expect the detail to look a bit shabby at best (something the Reel Art version actually does 'well', IMO with its "dimpled" almost reverse-looking bird body, hollowed out feathers and lack of detail in the feathers). It's actually hard to sit upright even with a holder as the bird body is deep in the back for some reason instead of relatively flat (won't sit worth a darn on the Landron holder and barely makes it on the plastic 'dish' holders).