UPDATE UPDATE, PROPER REAL UPDATED UPDATE!
The blank, unprinted and undrilled badge arrived today.
He's got the profile absolutely bang on, EXACTLY as the original badge except for the inner saw tooth radius as mentioned a few posts back. The thickness is also perfect. My camera is at work, so I'll bring the badge and a NOS casing in tomorrow to take a few pictures and post them up for approval.
The inner radius won't be a problem, but I'm not going to touch it up with a file, so that people can see exactly what they will be getting, and how much of a non-issue it will be to stroke them with a file a couple of times.
I am extremely satisfied with the quality, and I am extremely picky!
Once the pictures are up (about 18 hours time, max), perhaps as many people as possible could comment to say it's fine (or that they no longer want any for any reason, it's not an issue at this point if you have changed your mind as no money has changed hands and no final order made) - I don't want to be stuck with a load of badges and be out of pocket.
After a couple of days have passed so that everyone who has indicated an interest can see the picture and say "Yay" or "Nay", I'll get on the phone and order the finished items, pronto.
Have to say, I'm delighted with the results so far - a perfect fit in the cover recess!