Quote Originally Posted by edwardb View Post
As I said in my PM, anything other than dead flat will show through. Tape may spread it out, but it will still show. Don't do it. Those 6-32's will work. So would 4-40's. Surprised you didn't find them at your local hardware. Mine has those sizes all day long. I also like these: https://www.mcmaster.com/97530A097/. I also routinely use plane old solid aluminum rivets and pound them with a hammer against a solid surface like a small anvil. Low tech but works really well. The aluminum is quite soft and bucks easily. https://www.mcmaster.com/97483A075/. The thickness of the material is fine. Don't feel like you have to bury the head of the screw (or rivet). Do the best you can. As long as it's holding against the tapered countersink, it's not going anywhere. One installed, whatever remains above file or sand flush. Those brackets are mainly holding in shear (up/down) versus normal stress. With three per and 6 brackets (!!!) you will be OK with a reasonable mechanical attachment.
Copy that, I added a couple more brackets on the passenger side to help support the grab handle with no glove box they are easily accessible. I def could have missed those 6-32/4-40's at my local ace, will make another run by there this week. They are starting to get to know me by first name there, I feel like Norm on Cheers I make a couple stops per week there since I started building this car.