I haven't got any advice, because I am seeking the advice. I finally got the Darth Sid hilt from an old TCSS order. The hilt is very small, and the inner diameter is only about 7/8".
I'm looking for advice in chassis building mostly, as that's what going to hold everything together. I've thought about maybe carving up some remanent blade material into a sort of chassis. It would be a perfect diameter fit...