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Lew,

How about RivNuts? You oversize the holes by about 1/32, maybe 1/16, then insert the nuts from the outside. They are attached like pop-rivets with a special tool or they can be installed with a bolt and a wrench. They are tenacious little whelps; amazing in shear and pullout. And they come in several designer flavors, SS, aluminum and the like.
 
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