I now have the anodized aluminum case prototype in hand, and I couldn't possibly be happier. This is also the first time I've made a design for something involving substantial amounts of reverse engineering where I managed to nail all the details on the first try. Everything lines up and fits perfectly.
Frankly: I really, really like how this turned out. Radii everywhere, and no visible seam! Totally worth the fuss.
I'm now sending the verified design to the Corian manufacturer to see if they can pull off this design in that material. If that falls through, however, I'm delighted to observe that aluminum makes for a fantastic option. In that latter scenario, we could have a group buy rolling in just a couple of weeks.
Note that this doesn't have the PCB and magsafe cable. Those are on the way soon hopefully.
Also I've shown it here with the risers installed. Unlike the original RF itself, It can also be used dead flat (my own preferred orientation).
I look forward to hearing what you all think!