Made some progress here. Made some mistakes but that's fine. "We learn more from our mistakes than our successes."

Mistakes:
1. Use a release agent on the inside of the form.
2. The pins on the large plug are hollow and potting epoxy is VERY viscous
3. Use more hot glue. Did pretty well but there were a couple of pinholes the epoxy found

Will update with completed pics after I cleanup the cardboard the epoxy wouldn't let go of. Overall, this turned out pretty nicely. It will survive just about anything now I think.

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2005 X5 4.4i Build 04/05 Maintenance/Build Log
Nav, Pano, Sport (Purchased 06/14 w/ 109,000 miles) (Sold 8/15 w/121,000 miles)

2006 X5 4.8is Build 11/05 Maintenance/Build Log
Nav, DSP, Pano, Running Boards, OEM Tow Hitch, Cold Weather Pckg (Purchased 08/15 w/ 90,500 miles)

2010 X5 35d Build 02/10
Nav, HiFi, 6 DVD, Sports Pckg, Cold Weather Pckg, HUD, CAS, Running Boards, Leather Dash, PDC, Pano (Purchased 03/17 w/ 136,120 miles)