April 26, 2015 – If you have the time, tools and inclination, you can make a duplicate cast of a lightsaber hilt from a single mold of your favorite lightsaber.
The video runs a bit long (35 mins. 21 secs.), and most of us would not even attempt to make a mold and cast. But still, the video is an interesting look at how it’s done.
How to Build a Custom Lightsaber for Cheap! (31 July 2014)