Wow Peter, the MK5 is looking great! I like the changeable (/removable?) LED idea.
I've been away working for a while, and I have been trying to catch up on all the threads. Lots of cool stuff going on.
I may have missed it, but where did you get the micro switch? I would like to try something like that in my JB. I haven't decided if I want to use an actual switch or a mechanical connection. I finally worked out the button design for my 'pocket mod' (epoxy mod), and it seems to be working well, so I may just try to incorporate that into the JB.
What type of finish are you planning on doing on it? That's one of the issues I am trying to work out with mine. I've tried several different things but none are meeting my standards. It seems like spray paints take forever to cure. (It takes about a week before I can't scratch it with my fingernail.) I have also tried fingernail polish which turns out to be extremely durable, but difficult to get in a nice smooth, even coat. I even tried to add food coloring to the plastic itself before I poured it in the mold (that went over like a bean sandwich), the food coloring immediately turned to clumps, and the de-molded piece was speckled and stains anything it touches. Not sure what to try next, other than to get some color tint made specifically for the liquid epoxy I'm using. I'm skeptical about what that will look like.
Anyway...nice work. Can't wait to see pics of the finished product.