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M6 is already a good choice over M5, plenty of people I'm sure have overloaded a Bagman which relies on a single M6 bolt. The advantages that Voile straps or klickfix have over a system like this is that the fatigue loads of it bouncing around aren't applied directly to bolt heads. Voile straps are inherently elastic, and the failure mode of klickfix is just rotating around the bars.
I have no doubts that made properly, this system could be a decent compromise of weight and strength, and I would trust you to make it properly!
chiroshi
Hulsroy
Good points. Other have done four bolt faceplate rack (eg. Hunter Cycles).
Maybe I will spec black hardende M6 bolt rather than stainless.
I have a feeling the rack will bend before bolts shear. But atlas I am no engineer.
Re bouncyness. I think that a bit of flex doesn't matter and my thinking is surely its better than the klickfix stystem or voile straps+drybags+foam spacers??