strut fitting bolts

[Jesse Jenks]

Hi guys,
Here's my latest dilemma: I started up drilling the holes in the struts that
go through the ends of the strut and fitting block. I had done up to 3/16 in
the drill press (blocks only, not struts), so I had straight holes to start
with. I bolted them together with a couple 3/16 bolts and started drilling
the other holes up a couple drill sizes at a time with a hand drill. I
finished with a .248 reamer, and everything looked good, until I saw the
back side of the holes. The holes wandered off center a bit. The bolts fit
tight, but on the back side the hole is oblong. Imagine two different holes
starting from the same point, and finishing at slightly different points.
It's not that bad though, like I said the bolts are snug, but on one face or
the other the bolt is not fully engaging the strut material.
I have three options as I see it:
1) build new struts
2) drill out to 5/16
C) not worry about it.

Anyone been there and done that?

Thanks
Jesse

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