If I attempt this, it would have to be with all hand tools. I have no drill press. I do have a ton of hand tools though, & Dewalt & Milwaukee power tools. Rounding the screw head can be done. Rounding the radius would have to be done carefully with much checking. You Sir are very good at what you do.
Your idea of using the beefy escutcheon is a great one. You could easily start installing these for $50.00 a gun and cost of parts & shipping. Your work is that good that it is definitely professional grade. A Man set up with a Machine shop is a VERY lucky Man in this hobby.
Again Terry, best install I've ever seen. As good as any master tuner I've had do this to. Thank you and GB!