The latest enclosure samples arrived and they work great! The first full order is under way, then we can finally move into the beta.
The change is depicted below: the new top piece (right) has two ribs added to prevent the card from catching on the inside edge as it ejects. Now it's much smoother.
Also, the enclosure folks finished the pad printing jig for the actuator. Now it has red on one side to indicate the card is not read-only:
You can check out more pictures on flickr. :)