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tl;dr - Got sucked into this hobby a couple months ago and now I have my first custom PCB and firmware working. You check out the source files here.
The Keyswitch Kicad Library ended up being invaluable in exploring some of these questions.
There was also one more reason I chose the RP2040 - I saw quite a few RPi Pico boards at Yushakobo, including one called RustyKeys. The firmware for that board showed me how simple it could be to write my own keyboard firmware and was a major source of inspiration. Just knowing that something can be done makes it a lot easier to do it.
While waiting on the switches and keycaps, I started writing the firmware. I started with my rp2040-template I made recently, and drew heavy inspiration from the Rustykeys project I mentioned before.
For the design I'm thinking (Iris)[https://keeb.io/collections/iris-split-ergonomic-keyboard] that can break off into a Corne. With an arrow cluster in the corner - because I need my arrows.
If you are still designing the plate and or case i would highly recommend using KLE to define your layout and plate builder. It generates the plate design and saves you a lot of work.