1) What part of the screw do you really need to clamp your assembly? That is, do you need the external threads on a cap-screw type head, with the internal hex not needed to go all the way through?
Do you need the internal hex opening all the way through the shaft and head, or only in the cap-screw head part, or only in the shaft part?
Can you live with a round hole at one end or the other? If so, would that round hole need to be larger than the hex opening (tip-to-tip), or internal to the hex openingflat-to-flat?
Do you need external threads at all, just on the end of the bolted shaft, or all the way up the external bolt shaft to the bottom of the head? Can the cap-screw head be square or hex itself? Knurled?