I'll try to answer all questions as best I can:
PG, I have the designs I can email you, but the design was done in Pro-E (Pro Engineering) format. The design procees was done by the highly qualified aerospace design engineers here at work, and that is the software they use so if you have that software, I will forward it to you after I sneek it past our "intellectual property" screening process.
R&D, as mentioned, took a period of "many years" as stated in my original post.
I decided not to anodize the aluminum, so I did not reference any mil spec. Had I done that, it would have been to Mil-A-8625 Rev. g
The engineer's wifes sent them sack lunches.
As far as the environmental impact study, it does not apply to me, you see, I have a Govenor's Permit.
Chump:
http://www.permatex.com/MSDS_data/msds_files/81158.pdf
I keep a copy of this in my glove box
ramit87: Although silicone has a low VOC content, I still used a VOC recovery system (system certified by my Gov's permit). Also, don't you be bagging on the EH&S guys, we are so un-appreciated in our annoying, but necesary tasks!
macario: The distributor is shiny because I just sprayed it with a water reppellent spray, I am relentless in my anti-moisture campain!!
but I should have mounted it a little higher.
