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I made a replacement for the Chicago Screws. They held up well at the Nova Mini Maker Faire. http://www.thingiverse.com/thing:266673http://www.thingiverse.com/thi...
There are limited options in the customizer, but they are completely customizable with the .scad files. The ones I made were 3.5mm for the outer sleeve. They are at least good during prototyping. If I made one for someone, I would order the proper screws. But these would be good to check the fit and function.

Fastener (Replacement for Chicago Screw)