Sweet. Thanks for the explanation about the voltage jump, guys!
Pictures attached to this post.
This was my first time working with external heatsinks. I underestimated the difficulty, and ruined one sink trying to hand-drill it. Total fail. Luckily, I discovered that a colleague owns a Tormach PCNC 1100, and he was kind enough to invite me to his workshop and let me use the machine. A gorgeous device, let me tell you. It made short work of all the drilling. Then I hand-tapped all the holes (I think the Tormach machine can tap holes, but I wasn't sure how to keep the oil flowing and the taps clear of gunk for this operation).
The heatsinks themselves took some finding. They are Fischers, 10mm high by 300mm long, with 40mm fins, part SK 56 100 SA. High quality, and hard to find in the US. With 10mm standoffs, the entire amp fits nicely into an enclosure just slightly larger than 2.5U. (I also tried sinks with identical dimensions from HS Marston, and they sucked: all extrusions I received were crooked, and there was no way I could have bolted angle brackets to them.)
The rest of the chassis was done by FPE. In retrospect, I wish I extended the top and bottom panels to overlap the sharp edges of the heatsink fins, with large rectangular cutouts so air could still circulate. Still, I'm happy with how the case turned out. If anyone cares, I'm happy to share the .fpd files. Because FPE does not do anodizing, I had to have the panels made in two steps: one run before getting the pieces to an anodizer, and one run after.
The circuit itself was easy to assemble and adjust. No trouble from the Toroidy transformer. Overall, the amp runs a little warm to the touch (at 20mA output): cooler than either my KGST or mini-KGSSHV, though we'll see how it fares after more than an hour (all I've listened so far).
Many thanks to @mwl168 for the group buys and build notes, @sorenb and @jdineshk for the capacitor group buy and help, @vilts for making the spectacular titanium knob, everyone else who answered questions and provided inspiration, and many many thanks to Birgir and Kevin for making all this possible in the first place.