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Methods to screw aluminum to steel?

That my thought, insulated from aluminum and steel. Plastic washer for screw head
 
That my thought, insulated from aluminum and steel. Plastic washer for screw head

I'll have to look and see what's available. If that shoulder is under the panel though, the well nuts I've used, it would create a significant gap.

Anyone ever used plastic pop rivets? Just found out such a thing exists: https://www.essentracomponents.com/en-us/p/pop-rivets

They appear to be made in a size that is close enough to the #8 screws used for all the interior stuff too. Would seem to be a pretty quick and easy solution. Normally not a pop rivet fan, but for something like this they could be useful.

Would still have to insulate the aluminum from steel, but I don't dislike the idea of a strip of electrical tape. Simple and effective.
 
If you really want no chance of galvanic corrosion you could use scrivets. There are several different head types.

Or go with dzus fasteners.

As far as storage, I made some compartments near the back of the bed of my old K5. Cut the original side panel made a bracket to mount the panel and a piano hinge. The compartment door was held in place by the tailgate and a magnet. But once I switched to a truck tailgate that didn’t work anymore and need med a real latch.
 
If you really want no chance of galvanic corrosion you could use scrivets. There are several different head types.

Or go with dzus fasteners.

Yep, Scrivets are pretty much exactly what I was thinking of! Thanks for that link!

They also show plastic pop and expansion rivets at that site, which would also work I expect.

There are a lot of similar products out there, basically any sort of panel fastener that expands would probably work for me. They won't see much weight at all, and I would think as long as they were tight initially, they shouldn't rattle loose.
 
On aircraft related stuff dissimilar metals always had some sort epoxy as a buffer slash sealant to keep the two metals from becoming one
 
On aircraft related stuff dissimilar metals always had some sort epoxy as a buffer slash sealant to keep the two metals from becoming one

It will be interesting to see how this holds up. It does stay really damp inside for long periods. I don't think it will be catastrophic or fast if it starts to corrode, but I might as well do at least a bit to prevent/prolong the inevitable if I can.
 
Aircraft stuff was always be disassembled and reassembled, so the epoxy, which is always removed and replaced was never there for extended times.a
I think, for what you're doing you could do well with rubber grommets to seal it. Just take it apart once in while and reassemble to keep the corrosion at bay.
 
It will be interesting to see how this holds up. It does stay really damp inside for long periods. I don't think it will be catastrophic or fast if it starts to corrode, but I might as well do at least a bit to prevent/prolong the inevitable if I can.
I’ll see if I can find some of the push in ones in the garage. I can take a couple of pictures showing how they work. If not I’ll be in the hangar in a couple of weeks. We don’t go through them as much anymore, but there should still be some around somewhere.
 

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