Any easier way to file bed wear strips holes square

[72step]

So I made some good progress over the weekend and milled all my composite trex board for my 65 C10 stepside. I put it together as a mock up to test fit the width and by luck exactly 9 of the 5.25" boards fit perfect. So regarding the strips I didn't get the kit because I needed more than 7 and little did I know that if you order them as separates from LMC they don't come drilled so it's going to be a real PITA to drill and file 56 holes especially to file by hand. I did it on the angle strip covers but man it is time consuming and tedious. Any ideas to make this easier on me? A friend offered to loan me an air file. I've never used one so I don't know if it would work. Perhaps a dremel? I've never had one but I'm just trying to think. The only thing I can think of is to try and find button head bolts with an allen head or torx. I think that would be quite expensive and might not look right. Any ideas? Thanks.....Matt

[72step]

And yes those are holes you see in my trex composite decking. I picked it up on craigslist used for almost nothing.

[IADC43]

Really, the best and easiest way to do it to take them to a steel fabrication shop. Mark out the hole placements and they can punch them with an ironworker. You will end up with proper sized, symmetrical holes that you can use carriage bolts for a clean look.
I used to work in a fab shop and I guarentee you that would be the best way, and it wouldn't take them very much time to do it.

[jayoldschool]

I agree. I was short three of the offset washers, so I picked up regular stainless washer that I had to convert to offset with a square hole, and it was terrible to drill and file that stainless material. Get them punched, or, make a punch set up.

[jonzcustomshop]

or just get one of these:

Drilling Square Holes - YouTube

drill SQUARE HOLES Japanese form tool - YouTube

[earl84]

What about just drilling round holes and using the bolts that look like a carriage bolt head but instead of a square shoulder under the head they have what look like serrations under the head? Not sure but I think that may have been what they used from the factory. That's what was on my truck when I bought it, and that's the type of bed bolt kit that I bought when I redid my bed. They work great, super easy. Once installed, you can't tell the difference.

[72step]

Thanks for the ideas guys. I think earl84's idea is probably the most viable cheapest route to go. I'm sure a fabrication shop will charge me at least what they cost new in labor but likely much more. The whole broach idea is interesting but without the right skills I can already see me bending the strips to hell lol. I've found some hex button head stainless bolts online which I'm getting real tempted to get. The thing with the square shape it doesn't take much to round it off if you ever have to remove the bolts so the hex button head bolts would take care of that.

[72step]

What size are these bolts anyway? I'm thinking 3/8" on the angle cover bolts and 1/4" on the wear strip bolts???

[72step]

I placed an order for all button head socket bolts in stainless from the bolt depot. It will look different but there's nothing traditional about this bed lol. I will be returning the stainless carriage bolt kit. I will post pics and my thoughts later. Thanks...

[Captainfab]

Here are the ribbed neck carriage bolts you need for round holes.

http://www.mar-k.com/Catalog/PDF/Catalog/bolt_kits.pdf

http://www.mar-k.com/Catalog/PDF/Cat...are_pieces.pdf