Hey Tony,
as you know, I thru drilled the original frames on 338 and countersunk the outside frames where the new holes appeared to take a flat head. You could use the barrel nut with its oval head on the inside and use a flathead machine screw like I'm going to do - because they will sit flat and unimportantly in the roundness of the frame. If the inside frames are truly history then why not make them up out of aluminum or even teak? I think I would find something harder. But with a little trickery you could get the panheads on the barrel nuts to be almost flush too.
One other thing: all Ariel deadlight frames inside and out are exactly the same pattern shape Only because of the tiny screws going into blind holes is there handedness, and pairing, and there's inside/outside. But the point is that the eight frames could be cut, routed, or otherwise manufactured with a single pattern. Could be simplified totally if you thru bolted with a floater. Now I'ld be tempted to cut them out of phenolic mahogany marine ply and paint them, hell they might varnish up real nice too.
You can rabbet the edges of the frames so that they go into the hole a bit to hold whatever thickness glass just so. The original frames do that too. But absolutely nothing holds them to the cabin side. Made frames would be wider and would thrubolt to the other THRU the cabin liner and side. About a thousand times stronger.
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