Fascinating stuff.

I ended up doing it the hard way, which didn't turn out to be so hard after all. In the process I realized that 1mm is actually too thin, so I increased it to 2mm for stability. This is a part that gets screwed on rather tightly.



The underside isn't meant to be seen, so it doesn't matter what it looks like. I was just trying to remove as much material as possible for 3D printing purposes.

Michael, I know it can be frustrating at times, but just know that you're the hero for tons of us out here. I can't wait to see the new update. Keep up the great work.

Thanks to everyone for the ideas and assistance!
Patrick