Update: Mission Successful
well after a lot of testing trails I think we are onto the final product. Before I get into the results I want to explain a little about the testing performed.
As explained earlier, I wanted these pieces to be as "bolt in" as possible. Some will need to grind a little here and there but for the most part these should be fairly easy to install. I have tested pull out force on the inserts. . . lets just say it maxed out one of my gauges and required bend the test piece of poly into a U shape before pulling out. With 5 studs for each window these should never come apart. I also tested the adhesion properties of the blackout "frit" area that needs to be painted. Maximum adhesion is reached after 120 hours at proper curing temperature. Adhesion between RTV and the painted substrate was also tested. I chose several different flavors of sealer. All performed very well and showed very strong bonding properties. In all tests performed I was unsuccessful at pulling the paint from the polycarbonate after full cure.
So now on to the final result. I have installed the final product into my vehicle (p.o.s.) for test fit and for photos to those wanting to see something. The left side of my vehicle is undergoing repair and currently only has sealer. The right side is needing repair and is waiting, so the paint on the right side is sorry as well. Use your imagination and pretend the car has nice paint.
Now that a final product and methods are complete I will be working with the Admin here and others to make these available.