The reason I made the torque plates .5" is that I need .5" to actually thread a pinch bolt through. I will mill off 1/4" so that the net width is .5" instead of .75".
Also below is the port that I 3D printed. I am very please with the results. Molex has drawings for all their parts online, so it was very easy to use it as a reference. Fits perfectly.
Since it would be a pain in the ass to make a new top for this controller -- and since my enclosure is going to be completely sealed (already is everywhere except two spots at very top), I don't think I will go through the hassle. It looks cool this way too. It's heatsinked to the frame with thermal compound.
In this picture, the polycarbonate is on. In a future revision, I hope to reduce the side panels an the aluminum edges. Before I weld them together I will mill them down to about 1/4" high. Now, at least, I have a good reference template. When I first started, it was very hard to get the geometry/shape of the enclosure right without having a prototype.
Velcro strap holds the top most pack. The bottom long pack sits on 1/16" rubber.. snugly. All other packs are velcroed to each other.
I love how it looks! 20S5P A123