Thank you for interesting ideas, hamil_hamster!

As for your worries about externall antenna, I'm not sure why your modem got damages during *disconnecting* ext. antenna accidentally, but I would rather said about static burst during unexpected separation. I'm testdriving N900 with antennas connected externally (without sacrificing built-in ones), and I'm not experiencing symptoms you've described. I think it depends a lot on externall antenna design - having background in those things, I use my DIY fractal sets, adjusted to frequency I need at the moment. I haven't observed any negative copling between it and internal antenna, as long as everything that should be shielded, is.

Of course, it will require some sanity from user - connecting to-be external antenna port to lightning strike catcher isn't best idea, for sure Still, it will be "just port" - no one forced to use it, and when not in use, it won't result in much difference from having those hirose ports on motherboard (which every N900 got).

As for stamping internals, it's very interesting idea, but I don't have access to such tools - and, ordering it from somewhere near me, require huge quantities (or insane price).

I don't expect ever selling hundreds of them, so CNC milling, while not-most-effective for large quantities, seems best fit for this project scale.

/Estel