Mex,
What rectifier did you use for the Borg? I'm using some cased Schottky rectifiers in the bigger class A amps I build. IIRC, they are rated to 40 amps or so but their bigger brothers handle a lot more. These rectifiers run cool and voltage drop isn't that bad. I can pass along the parts numbers if you're interested.
I hope you and Mr Wiz can publish your power supply tutorials so some folks can get onboard with the manual charging.
BTW, I'm still working on getting some heat sinks down there to you. I haven't forgotten. My kids and their manageability take up a lot of my time, recently.