How should bolt holes be sized in relation to the bolt?

The sizing of bolt holes is crucial for ensuring proper fit, easy assembly, and adequate load distribution. Bolt holes should generally be sized to allow a small amount of clearance around the bolt to facilitate installation and to accommodate any alignment issues during assembly. The correct clearance typically recommended is 1/16 inch larger than the diameter of the bolt. This size ensures that the bolt can be inserted easily without excessive play that could lead to a weakened connection or misalignment during the installation process.

Having this slight clearance also helps with thermal expansion and contraction, slight misalignments, and vibration that can occur in structures. Properly sized holes help maintain the integrity of the connection while allowing for any minor adjustments during installation.