As I mentioned elsewhere, I did believe in Rossi (I've been following since early 2011), but, after going through all the court documents, I have to say that my confidence that he's for real is mostly gone (do read on to see why I still have some hope). For anyone familiar with scams, things here read much like a scam - it's about the kinds of players involved, common operational/tactical manoeuvres, etc. I'm familiar with the way these typically play out after having a friend scammed. He later, to get some sense of revenge, baited and played along with another scammer to see how far things would go. Around that time I spent some time reading about scam baiting (this is a real "sport", see 419eater) and so got to see how a scam usually unfolds. With the court documents, you can get a better sense of how things evolved over time and having the exhibits for reference is essential to picking up more nuanced details.
So, I do see quite a few things that point the way of a scam, e.g. the way Rossi put pressure on the decision to go with the Doral site (or else the opportunity would be gone), fake-sounding names, cheezy business cards, implausible manufacturing space, etc.
At the same time, though, there are a some factors that don't really fit with the idea of Rossi being a typical scammer. More than six years is too long for this to be a common scam. Rossi has evidently put his health on the line here. He is the one who initiated legal proceedings (is there documentation of another scammer having done this?).
One possibility, as others have mentioned and which I agree could be the case here, is that Rossi is deluding himself and is honestly working in the hope of finally getting the technology right. The thing is that this explanation really doesn't square with the blatant signs of scam. The only way that you could have a genuine, hard-working person being able to overcome the ethical dilemma of creating the illusion of a real scam is if he was desperate or paranoid enough. Desperate he could very well be after sinking his savings into this at his age and paranoid we know he is from his behavior wrt Krivit and others, his postings, etc. (I'm not saying it's always undue paranoia, but it's undeniable). Given these considerations, I suppose it's pretty clear where things stand.