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Steal some ideas from gripper mechanisms. A lot of times they're doing this exact kind of motion.

Real world structures are not perfectly rigid.

Those are maybe the worst kind of screws you could've chosen. Conical head of the countersunk screws aligns itself exactly to the conical hole. But if the threaded hole on the mating part is not in the exactly the correct position (which it never is, because real world is not ideal), the screw...

Are those slotted countersunk screws?

It's true that bolt head and nut would protrude, but OP already agreed above that one flat plate + one bent plate is an OK solution, so I'm not sure he's worried about protrusion. Also, looking at the pictures of some guard rails (example), it seems it would be possible to hide the protrusions...

Why bend the plate and not just use flat plates with a longer bolt? What purpose do the bends achieve? With flat plates, you can have the width of the bolt hole pattern just slightly larger than the W, which will minimize the deformation of the plate, which will minimize your projectile worries...

You're saving $100.000 by using a couple of stiffeners less per wall? Several of stiffeners comprise 25% of the cost of the entire project? I don't understand, where did you pull that number from?

It seems you're overthinking it a bit with the choice of stiffener type. Most likely, that particular type was used because it was the simplest one to use for one reason or another (e.g. same profile was used someplace else on the structure, or company often uses that particular profile in...

It may be if you don't care about the bolt head being fully submerged.

I mean, the dimensions of the counterbore have 0 effect on the performance of the bolt. It's all up to you and your specific situation. If the hole is too large, the bolt won't perform any differently. Bolt doesn't even have to sit in a counterbored hole. It can just sit on a flat surface like...

OK, and what's the importance in your case? You have told us exactly 0 information about your case. The questions I asked are meant for you to analyze your case and determine the range of acceptable values for your specific case. Again, what happens if the hole diameter is too small? Under...

Does it matter? What happens if the counterbore is 0.1mm wider than some supposed "ideal" diameter? How about 1mm wider? How about 3mm wider? How about 10mm wider? Same question for depth.

The way I understood the problem, there's friction holding the two parts in place, but you're worried that the friction is not quite enough. If you use pins, the friction will still be there doing its job. The load the pins are going to bear will be equal to the total load on the part minus...

Hole-and-slot system for pins provides exact constraint without the need for tight positional tolerances.

I've used a pair of cylinders in plenty of similar situations. Synchronization is generally not a concern if the structure being lifted is rigid enough (OP's structure seems to be), the length of pneumatic hoses going from the valve to each cylinder is approximately the same, and W/H ratio is...

Much better. Though, by the looks of it, you seem to have a welded structure without any machining afterwards (maybe it just seems that way because the model is not complete), and you likely won't get good straightness / flatness / perpendicularity on those surfaces. General practice is to...

With only one bearing per rod, the system will definitely bind. One bearing is not enough to constrain rotation. At least two bearings (spaced reasonably far apart) on a linear guide are always used. Though, if you put 2 bearings on each rod, the system will be over-constrained so you'd have to...

Why not use a jib crane?

You've got two options: You can spend hours trying to come up with a calculation that will be questionably accurate (while also using questionably accurate "worst load cases"), and still end up having to test it because you can't rely on calculations alone or you can just build a simplified...

Any reason why you're trying to design this from scratch instead of using one of countless commercially available taper lock bushings?