didn't Hughes or someone have a 2 piece tray ? was a lot of complaints of leakage at overlap . that may be the hardest area to seal ?
maybe the folded edge will help this by being stiffer . maybe have a threaded bar spot welded to the plate rather than use sheet metal screws at least then they wont tear out
Tex
that's a good idea tex. maybe, with a "captured" bar instead of spot welding the aluminum. you could still put a stiffening bend in the middle, but have a couple of extra "tabs" down the length that could simply be folded over the bar, holding it in place. don't know what kind of equipment andy has to facilitate this arrangement though. sounds just like an engineer. take a simple idea and complicate it a bunch, then require extensive special equipment to manufacture. write up comprehensive, complicated instructions for installation and use, then set up exclusive marketing networks to distribute.
still a good idea though ! what ever andy decides, it will be a great product.
