Everything is done, FINALLY! I milled the buttons this afternoon and that was a finicky job. Working with round aluminum that small to file it down to fit was time consuming. I did a test assembly, board in the enclosure with buttons installed, display plugged in and a battery clipped to the board. Everything works fine. I can't say I'm a fan of the onboard fire button on the DNA40 though, but it does work and that's what counts.
Finished parts -
You can see the guide rails for the board/battery contact sled and the cleat to fasten it into the enclosure. The bottom cap is the one with the brass contact on the door. Right now the back half of the atty cutout is installed and waiting for the JB weld to dry. I'll put it together for actual use tomorrow. The anticipation is killing me. I've also got to install the battery tube, but will use silicon adhesive for that.