At the moment I find that the 1/8" thick plastic is sufficient to handle the loads. Axially I can apply as much force as I can muster and the peg will not bend or pop off the rail. If I apply a large side force the footpeg will pop out of the rail. I want to use it as is for a while and see how it behaves before I go "fixing" it. My plan to prevent the footpeg from popping off the rail with large side loads would be to secure a wooden block inside footpeg close to the tabs.

I have not had any problems with the footpeg becoming dislodged accidentally from position. The fit between the rail and the footpeg is tight enough that it will not slide on its own but with a small force will slide easily along the rail.

The width of the various slots and grooves on the rail are rather arbitrary. The side groove the run the full length of the rail are wider than they need to be but must be wider then the thickness of the plastic to allow the footpeg to rotate. The angle of the adjustment slots match the angle of the footpeg tabs that catch into them, 45 degrees. I made the slots two radial-arm-saw-blades wide to allow lots of opportunity for the tab to catch.

Thanks for the questions. I'm going to add the above to the web page.

Matthew

:wq (for any vi editor folks out there!)