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Paul, I doff my cap to thee! That was a real lesson in mold making, casting and even a bit about milling! Your careful analysis and execution is a lesson in itself- planning is everything! Your presentation pulls it all together and I think you've nailed it.
A question- how long did it take to mill out the wing? I did use a crappy Dremel drill press with the Dremel tool mounted in it to mill the undersides of my u-boat decks to open up the drain slots. It worked, but was messy, loud and took quite a while.
Thanks for taking the time to prepare this wonderful episode - cheers, my friend!