Did some research on making them from Lexan(PolyCarbonate) and found a real eye-opener. From GE specs:
Do not use countersunk head screws as the ‘wedging’ action of the countersunk head causes excessive hoop stress on the sheet. This can
lead to part failure.
Guess what type of screws are used in the typical aftermarket windwings
Looks like I end up copying how Superformance does theirs and just using a truss head screw on the new Lexan wings I am making. Not as pretty but I don't need to continue to feed the monster.
Thanks for the input
Paul
in case you're curious, this is a link to the
GE specs