The need for this would become much more obvious as you address building the next levels of the box trailer. The cantilevered cross members should have some type of edge interconnection to define the outer perimeter of the frame.For a bolted construction I see a severe shortage of triangulation designed into structure to keep it square.If you used a hack to make the round hole big enough diameter to accommodate the square tang then you have lost the precise alignment that you mention in your question. Unless you intend use dozens of hours filing round holes to square the carriage bolts are not suitable. Carriage bolts with the square tang under the head are meant to be used with wood.Box steel with just 3mm thick walls can deform when squeezed under bolting pressure or when subjected to torsional pressure when bolted through the box. In my analysis your design is not going to be adequate. My question is will this design be strong enough without welding? I'm aware that welded joints are generally stronger. If you want to have a look at the model it's here. Each part will be individually painted after machining, and the interiors treated with rust preventative. The axle, 550kg suspension units, and hubs are being purchased as a single unit from a fabricator. Where the tongue meets the draw-bar two 5mm steel plates sandwich the join to prevent twisting. I am aware that my bolt-holes will need to be very accurate, and to prevent slippage I intend to use nylon-lined nuts, shake-proof washers, and locking fluid on bolt threads. I've designed a simple ladder chassis in 50x50x3mm box section steel, and want to know the viability of simply bolting these parts together like so: I'm no steel-worker though, and thanks to where I'm located getting a mobile welder out here won't be cheap. For now I'm focusing on the chassis itself, as once that's built I can use it to haul the rest of the things needed for the box.
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