I still need to make some jigs for cutting the holes and work with @nicksdad to figure out the grill situation, but I’m happy to say that, Gary, I’ll be bringing this for you to Ticonderoga.
Now that I’ve worked out the whole process, casting and polishing a single one of these took me three days and about 5-6 hours of active work time (to say nothing of a sore wrist from the sanding and polishing). But I’m happy to report that it’s totally bubble free, absolutely clear, and made with a UV resistant performance casting material that shouldn’t easily yellow over time.
To get around the sticky surface issue (the Crystal Clear takes about a week of proper curing before you can demold it without leaving fingerprints), I bought a HotLogic Mini, which I use as a post-curing oven. It happens to be just the right size and temperature. Six hours in there and you can de-mold it, but this has to be after the 16-hour room temperature cure time in the pressure pot.
The issue that @JoeB raised or parts floating around the mold did turn out to be an issue. I unfortunately had a dud casting before this one where the circuit board migrated out of alignment after I closed the pressure chamber. The solution I found was to make sure I did the first pour and then the second pour within 30 minutes of that, before the first layer had fully hardened. This gave a gel-like surface for me to press the elecrtonics components into, which held them in place. On the dud casting, I waited too long and the component was able to glide over the hard flat surface.