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I definitely agree - I am going to be very cautious before drilling/shaping the aluminium bits. I have been a bit less careful with the steel, because they are just cheap bits of steel, so forgiving and I can start over if necessary. I think I am happy with the first evening's work on it, but that was the easiest bit.
I am going to try to catch @mdcc_tester 's ear and see if there is a sensible, non-professional approach to this. I am actually wary of flattening out the area where the trackends will sit, because it means removing aluminium at some of the potentially vulnerable points (namely the welds) but also not sure what I could add to get a nice flat surface without causing temperature issues with the aluminium (6061 is quite finicky in terms of heat treating I have heard), and without a tig welder.
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jdmitch
I am not an engineer, so have just a laic explanation, but could it not add some sturdiness, help splitting the clamping force on a bigger area? Maybe just a countersink with a washer? As said before it would be on the steel dropout on the inside and on the other side a recessed nut with a washer? Anyway, worth exploring all the options before starting drilling, a more scientific approach would surely be in order :)
I think @mdcc_tester will have all the answers!