Trimmed and prepped new batch of clips as I did the old. Ended up with a 10mm flange, and about 14mm wide. Weighed an adel clamp, clickbond and nut - 7g. Clip plus trimmed zip tie - 0.7g. And the bonus of much less nasty metal installed in my aircraft. Still a win! My form generated 45 clips.
[Timewarp: I posted a question about my clips on the Cozybuilders Google Group and got a reply from Nick Ugolini. He says he has hundreds of his 'bowties' on his aircraft, and if he needs to get one off just gives it a blast with the heat gun whilst applying pressure in the off direction with pliers. I attack my test piece and both flox attached and urethane attached clips just pop off nicely.]