I was thinking about this since your first post. I'm thinking personally, I would try using one of the food grade liquid/tube silicone. I would use aluminum foil against the build posts (as a wall) and if possible the side of the RTA cover for the other side. I would let the silicone into the liquid port (may be cotton for a wall) and then trim if needed. This might get you close to a seal you would be looking for. Just thinking out loud.
I like this idea a lot because silicone caulking is relatively cheap and comes conveniently in a tube.
However here's what I'm thinking...
Silicone caulking sticks to metal. And one of the reasons I try to avoid using silicone caulking in home projects is because it is damn near impossible completely to remove the residue that cured silicone caulking leaves on surfaces it has cures to without the use of harsh solvents. Even scraping it off doesn't completely remove the residue.
What I would need is something that I could coat the surfaces with so that the silicone would not stick to the surfaces when cured.
And also, I'm skeptical about silicone caulking because even though they say it's food safe, because it sticks like glue to smooth surfaces I think there may be chemicals in it that I won't want sitting in my RTA chamber. After all, why would silicone stick to a smooth surface? But silicone caulking does just that since it's designed to seal around smooth (often shiny) surfaces like sinks and tubs.
I'm beginning to wonder if
@HigherStateD has a better solution here assuming the Copy Flex stuff doesn't stick to surfaces like the caulking does. But it's more expensive and also does not conveniently come in a tube

. But I have not ruled it out as a possibility.
I have looked into the moldable ear plugs and have not ruled those out either. However, I'm not ready to make a decision either way.
The Sugru or (even home made Oogru) is out of the question as it contains glues. While Sugru is non-toxic, they themselves state on a comment on a Youtube video that it is not Food Safe.
From Sugru representative...
whilst both of our formulas (Original & Family-safe) are non-toxic, but are not certified as food-safe