I'm thinking microchannels... like Cathar's. Just a mass of copper with some gaping channels ain't special. It'll do the job, but at the expense of decreased performance and increased weight. Microchannel blocks can be lightweight and allow for increased surface area close to the heat source. And they need not wreak havok on flow either.
I don't know if this is doable with your casting process, as microchannels require a high degree of precision.
1/2" barbs are a must for easy compatibility with the majority of other WC components. I have a Gemini GF4 block with 3/8" barbs sitting around because I can't figure out a way to connect it to the cooling loop without killing flow.
Whatever you decide, good luck with it.