Ok...these are rough but hopefully it helps make
sense of my ramblings...

This is the exploded view of the dual 18650 hammond 1590 box, the lexan plug that will be used to simply displace the silicone (note hole drilled into the plug centered in the future squonk hole cut out (I was a little premature adding the squonk hole at this stage of the drawing, I'll do that after the silicone cures, I'll pull the silicone out, cut the squonk and stick the silicone container? (don't know what else to call it) with some fresh silicone mix...I'm only using lexan cause it's already 6mm thick, I can give it a nice edge...and I have a .... load of it...

This is the 10mm shaved down 2nd 1590 box (screw lugs and PC card holders milled out, no squonk hole cut yet (as noted above), the plug is suspended in the box, the plugs upper surface is exactly flush with the top edges of the box (I think I want to arch the plug suspension over the edges of the shaved down 1590 so that there is no flaws in the surface that will eventually marry with the back of the mod, make
sense from a minimize the chance of leakage perspective?

finally, this is post cured and lexan plug removed. I'll wet brush some silicone on the outer edges and the top of the cylinder so it becomes one with the mod. I'll also mix up some 2 part epoxy to join the shaved down 1590 to the back of 1590 mod (not sure if it's necessary, cured silicone sticks like a mother...but meh, why not, plus when I wet sand everything down after I don't want a softish silicone line to contend with.
It's hard to show in gray scale but the cylinder that is seemingly floating above the squonk hole is part of the Dragon Skin pour (the hole in the plug?) and should provide enough spring back...the void will hold aprox. 20ml and the hole thing will add 10mm to the overall thickness of the mod...I understand that this is about as un-imaginative Volvo of a rectangular box but as a proto I just wanted to go big on the KISS until I figure out if this will work...so before you all say, ok sure, but that is gonna be some .... ugly unit there...I know
...one last thing...I'm pretty sure there will be some "shrinkage" in the curing process so I guess it'll probably over fill and razor the edges flush after?