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1. I went with outside to keep the box smaller.
2. I used delrin, wooden ones can swell up with humid conditions.
3. If your cutting away for the block the bearing will obviously be a lot weaker, you can retain a lot of the strength if your clamp block is a tight fit in the cut out section.
4. I drilled the blocks at the angle but getting the angle right meant trying to remember sine, cosine and tangents again ...... I think next time I will get some round delrin, then it won't matter !!!
5. the extra thickness won't matter if you drill the hole off centre so the bit that has to bend is not too thick.
6 Depends on how tight a fit your truss is in the first place. With wooden block I would err on a looser fit with wider split. On the delrin, there will be no shrink/swell so a 2mm split is all I cut (cut on my slide/comp saw)
7. Route the corners, drill screws about 12mm in from corners and countersink.
8. the angle needs to be pretty spot-on or you will have to jiggle the pole a lot to get them in.
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