Hey, I've just read through your log and it's looking pretty awesome! I'm building something really similar (flat) and in a different configuration. You might have done this already, but I found it really helpful to make scale cubes of the components out of paper/card and arrange them by hand to see the tolerances between parts. I'm also using sheet steel for the shell and was able to print the CAD drawings on A3 paper and then test stuff Ike the IO port measurements. Look forward to seeing the final design dude. Keep going!