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Mike,
I haven't seen Tommy's bar up close, but I suspect he has used "slip tubes", smaller diameter tubes coming from the top bar, with the down legs slipping over them? If that is the case, we simply drill and tap from the front to back at the 90 angle you are talking about and tap the inner bar for 1/4x20 button head screw. Bolting all the way through at that point is not necessary.
DV
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