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It seems like you would want a Lexan box anyways, for safety. No matter how well it's designed, there's no way to prevent a metal shaving getting in there and zapping the whole outside. The last thing you need is someone sueing you into oblivion because they were lazy and careless.
You don't need a very thick layer to trap EMI - heck, you could do it with aluminim foil or a cannibalized mesh garbage can.
I love seeing this project 'go pro,' but remember the little guys here!
EDIT if you're worried about heat dissipation, what prevents you from wiring up a little 10W 12V fan to the top of the heatsink? You can get them dirt cheap for computer cases.
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