MOTM

I *might* be able to use 10ga steel flat stock. It is 0.134 thck (nom).
Allowing for slop,
if the panels are 0.125 and the screw is 0.250, that means 9 mils until it
hits wood!

But, I *think* (and will need to verify) that standard '1/4 " screws' are
really like 0.219 long
from the end to the bottom of the head. Also, I need to get the minimum
thickness of the rail stock.

I really don't want to use 3/16" screws a la Moog: too much weight! The
screws would only be about
0.055 into the support bracket.

The current 11ga rail is about 0.113 nominal thick, and the screws go all
the way through it.

Or, as a (shudder) cheapo alternative, use flar bar alum stock that is 3/16"
(0.187) and use 1/4" screws.
The issue there is the silver alum "peeking through", and the fact that
tapped alum holes are only good
for about 10 insertions and then you get stripping. Or with Hendry one good
twist with 800ft-lbs.

I may just quote 9ga and 10ga. 9ga rails would weight a ton! Beat polar
bears to death with them! And forget
"use a hacksaw to trim" HA!!

Once decided, I could have these made up in about 3 weeks.

Paul S.
the King of Over-Engineering