Like I said it is complex making ram blocks, especially for a 9X series card.
The trouble with using a copper plate, is the surface mounts that are around the ram but higher, (as mentioned in my 9700 build article). To avoid these it would have to be a very complex shape or relief's would need to be milled.
I've been looking at detailed close ups of the Asus 9800Xt (digit-life) to see if my 9800 pro cooler would fit it, (I want the temp monitoring of the Asus GPU & Ram). Although the ram layout is the same they have repositioned the holes between the ram. My cooler design doesn't use these holes but in repositioning them they have moved some surface mount components. To make my cooler fit I'd need to mill some extra relief's, and there might be other things I wouldn't be sure until I have the XT in front of me.
In this sense milling the complete base about 1mm except for ram sized protrusions, (like other peoples designs), would be a better idea in hindsight. The truth though is we will never be sure what the next cards layout is going to be, so can't really make any design future proof...
Also what tooling do you have? the previous link I posted (you posted in that topic) used a post drill and the hydrae block (do a search here for it) was also made with basic equipment and a lot of time / dedication........
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