You are correct that this idea has been bounced around a lot. Lately, I have thought about a different angle of approach to this project.
Most people focus on creating the blade effect. I think there is a lot of other aspects of this type of saber that could be worked up much more easily.
The Hilt: Pre- Vizsla's saber had a very distinct hilt in that it has a square cross section and a cross-guard. If I were going to make a saber like this, that is what I would start with. I am sure it could be made out of aluminum square stock.
The Font: that saber had a very distinct sound to it. I have heard that there are fonts of that nature already floating around.
Between the custom hilt and the font, I think you would be most of the way to conveying the image you want. Throw an Adegen Silver LED in it and a shorter blade (maybe a 28") and I think most people would accept what you are trying to be. Your idea about applying paint and then scratching some off would be a very simple and effect way to give the blade the desired character.
Most people focus on the impossible mechanics of the blade as a starting point. I think if you had a custom hilt, the right font and a decent Mandalorian costume...the short comings of the blade are easily forgivable.
