Thanks for the compliments and ideas. The default Snugtop install setup has a single bolt, a J-clamp with welded nut that wraps under the bedrail lip, and a lock nut that should keep the bolt from backing out. I reckon the first adjustment was needed due to seal compression, but I'm not certain about the second. The things are only supposed to be torqued to 15 in lbs, and I'm just hoping the initial loose setup -- 4 of 6 were loose enough to wiggle up/down -- didn't allow excess vibration to damage fiberglass bed rail part of shell. This being my 3rd Snugtop, I can say with certainty that their quality control has gone downhill (yes, I'm a picky bast*$d too), but I'm hopeful I will find a solution that restores my confidence in the setup. It's a disconcerting sound to hear the top edge of the shell ********** the back of the cab when you get a bit of axle hop in a break in traction :Wow1: - that was what did the most damage so far. They try to mold these things so closely to the contours of the cab that there's not a lot of room for frame flex, especially if your shell starts to wander. If there's a next time, I think this will be my last Snugtop.
I'll give some thought to the solution of bolting through bed rails. I don't like the sound of it, but that would certainly be the most secure with some aluminum plate to distribute force of clamp.
Cheers!