Case has been tapped with 8-32 tap, hinge attached!
Hinge lines up perfectly with the ouside edge of the sheet metal... but one small problem (which I anticipated) -- it can't close all the way!
Problem solved, mill a portion of the stainless out for the headcap to protrude through, and mill same relief hole in the baseplate. Everything closes up nice...
As I was milling out the groove for the hinge knuckle to ride in, diaster struck. Not because I dropped it, but because I was cranking the X axis and not watching where the work was going. I cranked it into the pillar on my millpress rig, and then a sickening SNAP. The spy was right, the parts are cursed.
DOAH!
No one was harmed in this update, and the damaged pieces will be recut. Until next update, my fellow modders in arms...