I have had good success using clip on Tinnerman nuts and PK screws on access covers. The Tinnermans slip on over the edge of the hole to be covered. They are quite thin and by rolling the edge of the access cover it lays flat. Another option is the Cessna method of putting a ring of .020 inside the hole and clipping the nuts to it so they are not exposed on the outside. Al's nutplate idea works fine as well and we used them where conditons required but they are more difficult to install, more expensive, and heavier. Countersunk nutplates are also harder to find.
Note you must use PK screws with the tinnerman nuts, not sheet metal screws.
Ralph Baker
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