The layered brackets idea works very well, I found it pays to not make the fit too tight because it's easy to add a layer of paper or two later but if the fit is too tight in the beginning the only fix is to remake the whole part. I eventually added a layer of printer paper to all the brackets to give them all a smoother exterior all the way around with one glue join on the bottom of the section where it can't be seen.
Loadtest was successful... it can hold 3 beers... pics later
