Would you be able to make those hole 'already open' if you used a mill?. make them overlap if you know what I mean?. I know a drill would 'snatch' if tried, but what about a mill?.
PS, I love your work Rotor, but I have to say your 'quick links' are
not quick to load on my 56k'er

.
PpS. do you put 'locator pins' in there to allign the threads?(barbs), when the two halves are assembled?. I could forsee some nasty thread stripping from someone who tries dis/re~assembling them thereselves

, iff they don't line them up perfect...