Ha, yes, I may be asking the impossible. I've tried using self drill screws, but can't get any with a long enough drill section for the thickness of material, but that isn't so long it comes out the other side of the box section. Unfortunately I can't disassemble after drilling either.
The assembly consists of lots of box section inserted end-ways into a U section, so I don't really want to drill a largeish hole at each joint, otherwise the U section will be full of holes. It is also highly visible. I can get away with a small hole, but not big enough to let the swarf out.
I may look at the expanding foam and see if I can spray it through a small tube like you get with WD40.
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