John,
There were a few more Mills grenades available for the Loos battle than 3,500, and they were used by units other than the Guards Division - as witnessed by the comments in quite a few of the War Diaries of participating units.
While some companies engaged to produce Mills grenades did indeed struggle to produce good castings (Vickery's Patents Ltd one notable example), some of the companies were very skilled at iron casting and would have ramped up production quickly. Towards the end of 1915 too many Mills grenades were being produced, compared to what were required and could be stored, and numbers manufactured were reduced in early 1916.
Regarding aluminium base plugs, as you say few will have survived the battlefield compared to brass examples. If not actually used in training or action, many were simply lost in operations. Aluminium attached to iron corrodes in preference to the iron, so after a hundred years buried in the ground, retrieved aluminium base plugs still screwed into grenade bodies will most often be in a poor condition. Again as you say, that makes for physical evidence being scarce.
Tom.