Earthing Problem?

Not enough info.

What is the environment?

Is this a new approach?

Have you considered aluminum's galvanic corrosion potential?

Wherever you compromise the anodize, you'll have problems.

Maybe if you paint/pot/grease the junction after assembly?

Need details.

We earth extrusions by including a feature to accept a self tap screw but our equipment is used in fairly benign environments. The previous comment about corrosion should be taken seriously.

Our application is an electrical distribution system, so the environment is clean, dry, & internal. Your comment is good, but there is still the eye terminal and the screw to place, and the crimper and the screwdrivers. I was thinking along the lines of a extruded section feature and a Ctap crimp. Has anyone gone this rout?

I should have elaborated further, we use the self tap to retain an eye tag but this relies on earthing through the screw as the tag is held against an anodised surface.

I can't imagine how you would get an extruded feature that you could crimp to directly without having to machine it in some way first.

Flexjohn, in your post when you say "..but there is still the eye terminal and the screw to place, and the crimper and the screwdrivers.", are you telling us you would like to reduce man-time in the assembly of the ground strap?

If yes, you might try these guys: http://www.groundstraps.com/index.html

They have a large standard offering, and I think they will produce to your specification in quantities required.

Good point made about the toothed underside of attach eye... break thru the anodize. Otherwise, as already mentioned, it only grounds thru the screw threads.