The tolerances of ordinary bolts, including AN bolts, don't accommodate that. In measuring AN bolt diameters I've found as much as .002" variation. Industrial bolts are no better. Hi-Locks, close-tolerance AN bolts and NAS bolts are far more accurately made.I think that drawing in might also work with a grade 5 bolt. Then cut off the extra threads with a 4" abrasive wheel.
Well, I don't have that Airbus or Boeing high tolerance tooling drill guide either. So what to do? I tried several reamers and without a perfect drill guide I can't get a nice sized hole.The tolerances of ordinary bolts, including AN bolts, don't accommodate that.
The Hi-Lok pictured in post #22 is a reduced head, flush, shear. nominal sized fastener. Note the emphasis on 'shear'. A flush head, nominal, tension Hi-Lok is HL-18. A tension Hi-Lok can be used in shear, but not the other way around. Also, one doesn't have to have a Hi-Lok collar. MS-21042 nut with an AN960 washer is totally acceptable, and sometimes the only option in places where you can't get a Hi-Lok collar on. If using a nut on a shear Hi-Lok, one must be careful to just snug it up, not torque it down.That's not a traditional Hi-shear with a collar. Not a Hi-loc either. Looks like a NAS bolt. I found some flush NAS bolts with long threads but none with hex head. The instructions for bolt fit in AC 43.13 are limited.
Boeing also uses drive fit and nuts, not Hi-loc, according to my friend.The joint between the inboard and outboard spar cap sections of the HP-18 is similar to this. A diamond shaped splice plate joins the two, with 12 NAS4703 screws in each cap section for a total of 24 screws per cap, 48 per spar, 96 per wingset. You carefully drill up to #13, which produces a light drive fit on the #10 screw shank. Then you drive each screw in with a hammer or rivet gun, just like in the Maus video, and pull it home with an AN365 nut.
I don't know what a drive fit is, but I've done a lot of structural work on 727's and 737's, and there was lots of original Hi-Loks, also Huck bolts. Maybe that is what your friend is referring to.Boeing also uses drive fit and nuts, not Hi-loc, according to my friend.