GrayHood,
I've heard the forked emitter on the acolyte and disciple is very sharp and needs to be sanded. Are these people just over reacting, or should I sand it down? And if so, what's the best way to do it so I don't damage my hilt in any way?
Similarly as
=Ottomatix= has written, the method by which the shroud is milled creating the fork, it's not uncommon for there to be a sharp edge. Yours (soon to be) may not have this trait present and be completely fine and acceptable in your hands.
Much like an emery board, I personally use a battery powered nail tool that achieves excellent results. The products use may be unorthodox however I've had great success with it as it also includes a buffing pad and a polishing pad. Its use isn't limited to smoothing sharp edges either.
These are available in pharmacies everywhere here in Australia. Unsure if the product is available to you (presuming US) but an example of it is
here.
Hope it helps you as it does me.