Hi Ocracoke, thanks for the welcome and the help.

Im still running the calcs but it looks like I have the weight allowance to use 5-6mm HDPE or with a slightly different cutout 4mm aluminium. Ill try the HDPE first as its a bit friendlier to work with.

I have xt60 connectors and so could use them. Does it have to be able to be removed by hand? Does it have to protrude from the bot? Anyone have a pic of one in use?

I will switch to 2.4 then as there are lots of options.