I'm really liking the idea of putting the recharge port inside the hilt facing out just behind the speaker. There's really no where else to put the screw hole for a clip or a covertec button without drilling through threads.
I think I'm going to give a PVC chassis a shot. I'll put a connector on the speaker so that if I have to get to the chassis itself, I can unclip the speaker, and then screw off the ribbed section revealing the chassis. I'll cut a hole and mount the battery holder facing out, with a slot cut for the Blade Builder board (which is 1'' x 1'') on the opposite side. If all else fails, I'll just stuff everything in there (with respect to shielding and short-circuits of course) and be done with it.
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