So I've been attempting the "easy" task of changing out my ride plate and intake grates on my 2003 XLT 800's. (OK, so I've found out its not so easy...) Spun 2 of the four inserts for the ride plates on each ski. Now after reading the forums, I've seen that a good fix to this is to purchase some aluminum stock and drill and tap holes for the bolts. Seen the replacements from Island racing in another thread, but I'm pretty handy and can make them myself (I hope).

The question of the day is how thick should the aluminum be? The thickest I've been able to find is 1/2". Is this thick enough? Do I need to double it up so its an inch thick? If so, how should I attach the two pieces of stock together?

Any help on this would be great...