Very fast answer to your input, I will look at the pics and need to review your recommendations.
I am on a conference call right now, though what you’re saying makes great sense. I am just having a hart time visualizing it right now. The engineer that works with me has not gotten back yet on the....I think he calls it shear stats of the 1" solid but he did say the same thing about torsion flex... here is the statement in the E-mail he sent:
As a rough and ready measure 500 lb-ft on a 3/4 inch piece of square stock
would equal 16000 lb at a 3/8 inch radius, and that is assuming no safety
margin, which would equate to a material able to withstand 43,000 lb per
square inch, as a rule of thumb plain MS works out as around 16 to 20 tons
per square inch.
I will provide more date later today, have to make the customer happy as you request all the time you bastard!

John
Anthony