Speedbump wrote:Another thing I think is worthwhile is to make a special bolt length to do the job. I select the bolt based on shank dimension so the flanges and spacer holes are almost all filled with bolt shank, which is stronger and fits better, with only enough thread to properly engage the nut of choice and I NEVER use a lock washer in that type of application. It mostly requires cutting some of the thread end off and dressing the threads for the proper overall length. Aircraft folks have designed and used this type of bolt for years, mostly in SAE threads, but you can make your own with a little effort.
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