Actually it's an online CNC factory that gives an instant quote of around $15. So I'm thinking if I should future proof it to clear disc brake caliper mounting bolts, by adding standoffs, if I swap frames to the Dahon Launch. But without anything to reference measurements with, I will probably keep the strut flat. The launch also seems to have the caliper far back so maybe no contact with the struts.

Why did Tern use 6.2mm holes for the M5 eyelets on the dropout flange? Are there frames that have M6 eyelets? I'm thinking of reducing the hole to 5.2mm to improve stability of the rack.

The weak point is the hole just below where it clears the C shape profile, but the holes are 10mm intervals and that's just 2 holes apart, so if I want to keep it adjustable, there is always a hole at the point.

I have to carry everything with me, so I don't have any power tools. I only have small portable hand tools, at least enough to rebuild a bike. So that's why I'm looking at the online CNC/laser services.