Very interessting concept. I will not try to point out any problems right now because it seems that you have this game well thougtht out.
Part of the reason I have chosen to leave money in previous 401K’s is becasue I have have had access to some quality Mutual funds and felt that when I rebalanced or chang funds I avoided paying comissions. I try to rebalance 2 times a year. I have attempted to aggregate my portfolio excluding only the 529 which I opened in my parents name because they get the tax deduciton in NY. By aggregating everything together and then reallocating it oftem times means that there are a number of trades going on and by keeping them in the 401K I avoidhaving to commissions while simultaneously allowing me to take on a level of risk i am comfortable with.