...That Last Photo, I like That Look Best with the Louvers 'Tucked' Down between the Deck Sides and More Streamlined.
Last Night, I finished the 'Cold Thread Forming' Tapping of the 28 Blind screw holes. The 'Tap' (see photo) has No cutting flutes. It Squeezes/Swages the threads into the Soft Aluminum. It takes 100% more force to work it. It worked perfectly, feeling as if it could snap at any moment. Happy to report, No Errors. Will do a trial fit of all slats, today. No countersinks or deburring, yet. Will Post a Photo after.
Great Tap! the Only way to do Aluminum! No Chips to Gaul up the Threads, and they are Much Stronger because No Metal was removed and they were 'Cold Forged'!