XMIT wrote: Hooray! I hope I helped here, at least a little bit.
Definitely, you gave good advice and I'm using Kapton now.
So, how did this go? Both good and bad, in the end.
Kapton tape works well. It's really thin, though not the easiest to apply. After applying the Kapton, making sure to go around the corners to avoid the PCB getting contact with the plate at all, I had to make sure to remove the tape where grounding was applied, i.e. at the top where the grounding screw is and at the bottom for the grounded space bar.

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Kapton tape improved the treshold at which I was able to use the board without errors... by 1.

Not much, but it sure didn't hurt. I also found that key recognition improved a bit over time as the PCB settled and conformed better with the rounding of the plate. Possibly grounding was also improved by using two wires, one on the PCB and one on the plate, which were connected with the screw.

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What also really helped was adding the rubber mat back to the assembly, thus increasing thickness and overall tightness of the whole plate/PCB/plastic sandwich. I added the mat to the back of the PCB where it would provide only electrical, but not acoustic, isolation.
After that,I was able to find a threshold at which all keys registered, which is fantastic!
Typing feel was mostly uniform, but there were some outliers with a heavier or scratchy feel, possibly due to the barrel plate not being 100% perfect.
However, as I mentioned a few pages back the sound of this board is ridiculous. I did not expect it to be so loud, it is so loud that it distracts me massively while typing. That said, I have been using quiet boards in the last few weeks for use at work so my sense of volume is currently skewed towards quieter keyboards.
So, being in possession of a green prototype PCB from idollar's first run, I decided to try the option of including the mat in front of the PCB, between the PCB and flippers, similar to the original model M design. I hoped to reduce sound by this, and, in some way, succeeded.
I had to lower the electrical treshold significantly (by around 10 or 15) to make all keys work, and at that treshold, there were many incorrect keystrokes registered. Most of them were around the edge of the board. Currently the controller is set to ignore all F-keys and arrow keys, as I have frequent misfires on those switches. I'm currently using the board as a 60% with layers to achieve F and arrow functions. That way, the main alphas all work and register correctly, but the utility of the Tenkeyless sized board is much reduced.
Sound is also much reduced, but not in such a way that I would call it a quiet board.
Unfortunately, typing feel is much worse with the mat, heavier and less smooth overall.
I think I will put the mat behind the PCB again this weekend, just to get the full functionality of this board back, and then decide what to do with it.
My recommendation is to use the mat if your assembly is too loose, behind the PCB. Using it between flippers and PCB is not recommended with the final production red PCBs anyway, but I guess if someone were to try they would have to have a near perfect bolt-modded barrel plate, with perfect uniform pressure across the board, to achieve full keystroke recognition even on the edges of the PCB. This was a problem with my screw-modded version.
I've started floss-modding the springs, and while it will not reduce the DEAFENING volume of the keyboard itself, it will at least get rid of the ping.
In the end, this was a really cool, and fun project. You may lose some sleep troubleshooting the beast but when it works it makes you so happy.
Still, in the end the Model F hype left me scratching my head. I cannot see myself using this, or something like it, daily, as I get really distracted by the high volume.
Either way thanks to all people involved for making this happen!