Thanks a million for all the great ideas!
I especially liked the trilobular screw threads idea. I looked them up on the Taptite site:
formatting link
they are remarkable little critters indeed! The binding head screws are also a good fit for this project; I'm going to see if anyone makes a trilobular thread on a binding head screw. Several of you mentioned star washers, and that is also a good solution although it's either/or with the binding head screws.
Loctite is your friend, but in this case I need electrical continuity and multiple releases & reinserts, so I'd better pass on a liquid thread locker. Also, I've got no access to the rear of the busses, so peening the screw tips once inserted wouldn't work. I really liked the safety wire idea and the tablock, but the customer is low-tech and I'm unconvinced they would reliably restore the safety wire or tablock after maintenance work.
Thank you all for the help! Dave