The F knobs are kind of a struggle. First, I don't need legal issues. Second, with the skirt not a thin piece of aluminum they set too high IMO. The originals conceal the nut and make it set a good bit closer to the instrument. I am really open to suggestions tho.
Not sure what process you use? but couldn't you make a two piece mold? You'd have the main one and cap piece that would give you the underside shape and inject the resin or whatever. Never done anything like this so it's just an idea off the top of my head.
I can/do often use two piece molds. Problem is that the originals had a thin, pressed aluminum skirt. A two piece providing a skirt that thin made of composite would be too thin. I am currently in search of just the metal skirts so I can make the centers and attach them to the metal skirt.