MakerBot Print is our newest print-prepration software, which supports native CAD files and STL assemblies,
allows you to interact with all your printers via the Cloud, and many other exciting new features.
This is to confirm that I have shel measured by digital caliper from Hobbyking. I have 0.42 mm average width. Measured on two different parts of your model in 3-4 different places.
About servo cap fit issue I can say next.
Measurements of height of top "box" on cap (outside). Just at corners.
Front - 5.1 mm
Rear - 5.1 mm
The same places on wing_servo parts (inside)
Front - 4.7 mm
Rear - 4.2 mm
Probably there is kind of temperature deformation due to 0.4 mm shell or sort of PLA.
I think I'll cut top part of servo walls so, that cover will be aligned just by outer perimeter (wing profile).
In my models I do inner part (which should be inserted) on 0.8 mm less then outer part. This is exactly 2 nozzle sizes, 1/2 on each side from center line (coordinates) on each part.