I do appreciate everybody's suggestions on this mount. Designing a flashlight rail mount is choppy uncharted water for me. As each possible use for the mount is presented, like adding a magnetic feature, I consider if it is good to fold the concept into the mount itself or just declare it as a feature for whatever the mount is attached to. The case of a magnetic base falls in the latter. Nice magnetic bases already exist for machinist uses and I can easily see the light attached to one of those. Alternativly, it would be easy for anybody to glue a magnet to the GP mount or build up something specific to their requirements.
I have been working on the CAD model for the GP rail attachment. I took my computer with me on my vacation a few weeks back and got several opportunities to play with it. As you can see it now has two parts that are pulled together by a screw (not shown). It is now far enough along to start the first prototype. However, I am still debating on what metal to use for it. Of course the three likely options are aluminum (6061), 304SS and titanium.
One design concern I have is what will happen to the light if it is forcibly ripped from the mount. This is a likely event in several of the probable uses for the mount. If the light is on the handlebars of a bike during a crash, it could be smacked hard. On a helmet mount, the light could be hit on cave walls or ceilings. Another circumstance sees the light in a desk or wall stand and somebody not familiar with it just tries to forcibly pull it out without loosening the clamp screw. :shakehead
The goal of course is to not have the light suffer any damage. The issue is not about loosing the light as it must always be tethered in addition to the mount in cases where loss is a probability. Aluminum would make a good mount material as it could not damage the rail on the light (if it was not anodized). However SS and Ti could and probably would rip the corners off the rail on the 007 body. For this reason I plan to start with aluminum and see how it goes.
Cheers
Dave