The cover goes over the TOP of the rad support. It will bolt to the two unused holes that are in the rad support and sit on the lip of the radiator mate. Unless you chopped a hole in your support, it should fit fine.
It will be baz. That'll be a custom modification afterwards, let me see what the base thing will work out to be.
Putting a text cutout with a laser into it will create holes which defeats the purpose of having a cooling plate. I was looking into laser etching however haven't gotten very far with it yet I'll keep you updated mate.
I haven't modelled in the 14.5 degree bend 70mm from the top of the plate yet, am still drafting it in solidworks. Needed a flat version for the laser cutter
BTW: Solidworks says it weights 267 grams. Light enough for you all?