as long as the structure supports the base you can go pretty thin, like if your pins on the rotor block touch the top of the block it can go thinner, I would go with about 1/16" just to be safe.
I really dont think youll be able to get adequate clamping pressure with nylon bolts. See if you can find some other high tensile strength plastic bolts. do they make polycarbonate or delrin bolts? something like that.
On my block Im using 8 6-32 screws, clamping pressure is amasing I was conserned with heat transfer, but I just decided to try it and I can always change it later if necesary.
Jon
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