I am in the process of building these. Here are some notes:
-This model is 0.89 scale, due to the size of my print bed.
-I also had issues printing the hood, and fixed the areas with 90 degree overhang.
-The screen used for these STLs is http://goodlcd.en.alibaba.com/product/1889728595-212666913/5_TFT_LCD_Module_800x480_resolution_wide_lcd_panel_GD50TN33_GTT050RDH03.html . It is significantly lower resolution but only $60, and fits nicely with the STLs. The screw holes on the "backplate" STL should also align nicely.
-The lenses used are http://www.surplusshed.com/pages/item/l3786.html . They snap into the given STL files and the focal point is close to perfect.
-The padding is standard orange felt, secured with hot glue. The straps are cheap elastic bands also from a craft store. Overall, the comfort level is shockingly high!
-I did not use the 9DOF chip, because I figured I could always add it later once the rest of the head-set was operational.
Currently, my main issue is that the lenses create a modest gap in my view near the center of the screen. Also, there is a stark difference between my L and R viewpoints. The Occulus Rift solves this issue by splitting the monitor into two separate feeds, and I am having difficulty finding nvidia or 3rd party software which allows my video card to accomplish this in real-time. If anyone could point me in the right direction it would be greatly appreciated.