profdant139 wrote:
Lots to think about here! I may have to do some experimenting on scrap metal to find my comfort level. The hardest part will be finding high quality screws -- the stuff carried by the big box hardware stores is sometimes of lower quality.
Ductape, your comment about corrosion is interesting, since I plan to use (wait for it) duct tape as a barrier between the steel and aluminum.
Finding HS good quality screws has always been a problem. When fastening into thick steel frames,.125 or thicker I found if I drill a under size pilot hole and use the cheap big box hex head screws they will not snap off using a drill gun. I can't tell you how many I have had them break off without a pilot hole and they are very hard to drill out. To me the socket on the hex head holds the screw better than a Phillips or Torx head using just a bit. Also if you are drilling and installing a lot of screws upside down on your back it is hard to get them all in straight just using the self taping screws into steel. A pilot hole is easier to get straight especially if you use a "3 legged dog" or something similar. It will take longer but I think the job will come out better especially if you don't do this all the time.
