yo chris.... iv been in a similar position... it'll take weeks to to get a posh sofware package to do some exotic moves for the first time however after that you should have the same kind of job down to a day or two... maybe hours
still seems a bit of a waste if your not making 20 of the buggars

with a job like that id omit any non critical profiles and just take care of the luggs holes and recesses in mach wizards etc
unless your mate isnt in a rush, in which case you could use it as a training exersize and get stuck into some heavy cad/cam packages :)

ps: let us know how many you scrap :) iv seen your stash of delrin, you can afford it lol