Great stuff Ned and others keep it coming. Unfortunately, I have nothing to add to this thread, I can only take. I do have a question though.
I noticed in your photos that your cover has been dented in and it looks like it was creased by the brake lever bolt. This happened to me as well during a spill where the brake lever bent in and rode up creasing my cover almost to the point of going through. I was thinking about grinding down the sharp stuff on the inside of the lever or even welding on a small glider plate (say, a 1 1/2 inch square piece of metal) to the inside of the lever or even sticking a small piece of plastic on the case so the lever would glide on the case instead of going through. Any ideas?