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In the movie, it is shown that the operation and suit-up of Vader begins shortly after Palpatine finds him. I was reading an article explaining Vader's armor and it shows that a lot of thought has been made into every single detail of the armor, like the the edges of the helmet being made to deflect blows to the shoulders, the breathing aparathus, the whatever in the feet, eyes and so on.

Furthermore the helmet and shoulders are made from durasteel (among other metals) and the hand is forged from sith amulets.

The question is simple: How the force did Palpatine have such a suit lying around ? It looks like something which will take a while to create even if all the materials are avaliable.

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At least the clumsy design of the suit would be in accordance with a hasty assembly. –  Wrzlprmft Apr 27 at 16:17
    
A lot of force users could see quite a bit of the future. Maybe he did too and was having a plan for such occasion already. –  PlasmaHH Apr 27 at 20:52
    
Not to forget another component of the suit: The cape!! ;-) –  O. R. Mapper Apr 28 at 6:45
    
@O.R.Mapper - Now I've got a vision of Palpatine staying up late, slaving away at his sewing machine... –  Richard May 5 at 22:43

1 Answer 1

up vote 26 down vote accepted

According to the novelisation, the surgery on Anakin/Vader took "many days" rather than the few minutes we see in the film;

In the newly renamed Emperor Palpatine Surgical Reconstruction Center on Coruscant, a hypersophisticated prototype Ubrikkian DD-13 surgical droid moved away from the project that it and an enhanced FX-6 medical droid had spent many days rebuilding".

The armour itself (according to the Star Wars novels "Light and Dark" and "Tales of the Jedi") is largely based on existing designs for Sith Droids and General Grievous' armour, details of which we can assume Sidious would have had ready access to.

So, The Emperor had plenty of time, access to the most sophisticated medical facilities in the galaxy, unlimited resources, forbidden Sith plans as well as being able to use the Dark Side of the Force to help construct anything he couldn't buy off-the-shelf.

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