I can only go with 2"wide material on my setup. Every block I make will have a removable top so I need 1/4" minumum on the sides for an O ring as it takes a 1/8" pass for that. That leaves 1/16" on both sides of the O ring which is as little as I want to get.
or I can go 1/8" on the sides and hope the silicone hold with only 1/8". Which it did for a couple weeks on waterblock #2 on my website but that was only 2 weeks and I didn't test it any longer.
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