This explains it. I haven't had a chance to get any yet and I was picturing something 2-3 mm thick. Also making your rabbit a little wider than the teeth to allow the glass and VDS to "fold" down is a great tip.I don't know if you have gotten you hands on a piece of VDS yet, but keep in mind that it is very, very thin... like paper thin.
You mentioned that this makes the groove 7/16 wide. Looking at my preliminary drawings that means that the groove would extend slightly beyond the sidewalls and into the core. Same for your skis? I assume this is ok, and maybe even desirable
I don't need to steal your notebook if I can pry it from your mind one question at a time.