Bridgetroll:
That sketch is a good start, but it is still like pulling teeth to get enough meaningful info. out of you people. Is this an adjustable height splice (in 3" or 6" increments) of the two different sized HSS sections? What are the lengths of the two different HSS sections and what is the total load on that temp. column. Where in the height of this temp. column is this splice, and what is the total height of this temp. column? Am I right in assuming that you think you will have a total of 9 bolts taking this total load? Without literally match boring the 15/16" holes in the two column sections, which then become permanent mates which should not even be rotated w.r.t. each other, you will not get all the bolts bearing, without some bearing yielding in the HSS walls, at some holes. Can you even buy a 14" long by 7/8" A325 bolt? I do now see how you can get some bending in the bolts, but I still suspect that bearing on the HSS walls will be the controlling design criteria. In terms of bearing stress, you have the same reaction force (F) on the 3/8" outer wall as you do on the inner 1" wall. And, this connection may have to take some beam/column bending moment too.
Why don’t you show 4 - .5" reinf’g. plates on the left 10x10 HSS, and why are the holes at 3" o/c in the reinf’g. plate you do show? You mean the holes are at 6" o/c, but offset by 3" from one side to the other, don’t you? The only thing I can understand about the right section through the bolt hole is the 15/16" hole dia. I would have shown where that section is cut on the middle side view of the connection, and then shown dimensions .5", .5", .125", .375" (that’s 1/2,1/2,1/8,3/8"). No one understands your thought process in getting the dimensions you show, and if you can’t afford dimension arrows, that confuses things too. Now, on this bolt hole section draw a FBD (free body diagram) which shows the two triangular bearing stress blocks and the slope of the bent bolt. This is where some engineering judgement and experience comes into play unless you want to spend a day farting around with FEA on this detail. The left (upward) bearing reaction will be .33" from the clearance space and the right (downward) bearing reaction will be .125" approx. right of the clearance space, plus the .125" clear. Now draw your bolt/beam with forces (F) .58" (.33+.125+.125) in from the two outer reactions, which are about 11.5" apart. Draw the shear and moment diags. for this beam and take a shot at its slope at the reactions, and its center deflection. You will get some significant bearing yielding in the HHS walls and the reinf’g. plates, and most of that force (F) is on the reinf’g. pl., so is the 5/16" fillet weld enough. I would look at a larger dia. round bar material for the pins which met my bending needs and was somewhat harder than the HSS material. I’d weld a driving head to one end, and taper the other, as you show, and provide a washer and locking pin (cotter pin?) at the tapered end. You might also consider making the holes 29/32" dia. which will improve the bearing stress picture, but make assembly a bit more difficult. I would still match bore the holes and then consider only 80-90% of the pin cap’y; otherwise use a lesser pin cap’y., since all of them won’t come into play until some HSS wall bearing stress yielding has occurred. You probably don’t want any bending yielding or much bearing yielding in the pins or it will be tough to extract and drive them again.
If height adjustment didn’t have to happen at this joint, I probably wouldn’t use your detail. These temp. columns are going to have to sit on a base plate and some cribbing at their foundation; and also have some cribbing up under what they are supporting. And, I’d be tempted to try to do my height adjustment at one of those locations, and avoid this difficult pin shear/bending load transfer splice detail if I could.