If you look at my HOW-TO, you'll see I had pretty much ZERO "brim" on the ivanned strut I modified. And as I mentioned previously, you can probably have a slightly wider brim on each side (say 0.5mm each side) if you take a file and slightly widen the plastic slot in the arm rest into which the brim passes through where it's pinned. Again ... if folks file the plastic slot (and NO ONE WILL EVER SEE THIS) they can get away with a little more material left to CYA on the brims.
You have to be VERY careful not to take off too much brim, you take off a bit at a time, slowly. You don't want to cut into the threads. It's not hard, and I'd think you could do them on an assembly-line basis with a grinding wheel in about 5-10 minutes each strut. Again, I'd charge a few bucks for your time and labor and keep them at $50 a pop to cover everything.
Whatever the final count is on the struts, make sure you order some extras. As I mentioned, some will see your GROUP BUY post too late for the initial shipment, and will want them. Then you can hike the price for the late-comers to cover the extensive warehouse space and electrical/HVAC costs needed to properly store the extras.
Also, same with the plastic limiters ... say the final count is 5 sets of limiters. Order 8-10 sets (they're what, $2.50 apiece?) so you have a few extras for the stragglers. Also, you KNOW you will be needing at least one extra set for your burgeoning parts hoard....as with all good 500Eboard members.
Also, as I've found with GROUP BUYs, you will have about 20% of people drop out when it comes time to front the $50 (or whatever the final cost is). So you may want to have a few alternate folks (again if they come late and you don't order any extra struts) on hand to replace the dropouts.
If it matters, and you are close to the 25 needed......sign me up for a second strut if needed.
Cheers,
Gerry
thx Gerry! Yeah, the modifications don't seem like they are that complicated, even if the strut 'brim' has to be modified. I'm going to wait a bit to see if there are any upfront back outs, and then make the determination as to how realistic we can be about getting to the 25 level. Thanks for your offer of getting an additional strut to get us there!