That’s a bad estimate… Earth’s Moon is a friggin’ huge moon, and one 70% of its size would still be quite a respectably large moon. For a small moon, you want something more like Phobos (9.6e15 kg, approx. 20 km diameter) or Deimos (2e15 kg, approx. 12 km diameter). A spherical body the size of Deimos would be obviously artificial, so I’ll be generous and say it’s the same size as Phobos.
Now, for mass, I’ll assume that it has the same density as water, since hollow metal things made by humans usually average out to about that. This gives us a total mass of about 4e15 kg of metal. Now, the materials were probably close to free, since they probably have asteroid mining technology, but it still needs to be shaped, which probably means melting it down. Iron has a heat of fusion of approximately 2.5e5 J/kg, so we’re talking 1e21 Joules to cast the Death Star. Unfortunately, I have no basis upon which to estimate energy costs in the Star Wars universe.
But there’s more. This thing is mobile. I’m willing to accept that hyperspace jumps require a minimal amount of energy, but at the end of a jump, it has to match velocities with a planet in order to go into orbit. This means a delta V of around 30 km/s, so we can estimate the energy needed to be at least 3.8e24 Joules every time the Death Star moves to a new system. Since this is a recurring cost, and is so much greater than the energy to melt the metal, I’m thinking that construction costs are relatively negligible. When one also considers that the R&D was already done, it becomes clear why the Empire decided to build a second one on the same designs, despite the spectacular failure of the first.
As for those R&D costs, judging from the political and financial maneuverings in the prequels, it looks like the R&D was at least comparable to the net trade activity of a prosperous planet, over a period of several months. So we’re talking trillions of dollars, in 21st century Earth terms.
I suspect that the biggest cost, though, both for construction and maintenance, was for labor. What’s the average pay of an on-duty enlisted serviceman?