[Car5858]

I understand what you are saying Bill. Sometimes scale will be sacrificed for strength. In your case, the strengh is there.

As for cleaning up the channel after cutting, I have found that running the rail through a thickness sander cleans and levels the rails in about four passes @ .020 per pass. Just need to leave extra material to be able to do this.

I think that you can bevel the inside edge of the C-flange to reduce the extra thick flange appearence. Sometimes just rounding the exposed edges of the C channel wil improve the appearence.

Hope this helps

Carl