So the latest design hasn’t even been made at ponoko… and I already see it is flawed. I decided to restart from the beginning… now that I have a digital caliper, and understand sketchup better. Here is the latest:
I’m not rounding the corners till the end, because it’s easier to edit with square corners. Also, I’m keeping the the panels themselves 2D, easier to work with.
Prometheus Fusion Perfection 