Thanks for the great feedback!  Another design quick update:

Before I cut the 'toes' I want to ensure things are going to sit flat.  Here's a pic of my problem:

[ATTACH=full]56872[/ATTACH]

A re-design that takes care of the problem and improves my ability to adjust the toe shell laterally.

[ATTACH=full]56873[/ATTACH]

[ATTACH=full]56874[/ATTACH]

Sorry it's not a build update.  But getting this kind of stuff worked out prior to spending time in the shop saves much frustration.