Hi Bill:here is a picture of the chassis that we are prototyping. The wood panels on the left and right will have two holes drilled through them all the way... the bottom panel is 1/4" thick (wood or alum) and the top panel (cover) is 3/8" thick (wood or alum)...
so... we want to bolt in through the bottom cover (so that the hardware is blind) and go through the holes on the two side panels and then fasten down the top panel (blindly) with slight compression.
so... we just need to figure out the best way to get threads into the underside of the top panel if we use wood.
thanks for the McMaster carr reference.... your correct... not an easy site to navigate at all.
cheers and thanks,
msl