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Good comments! I especially liked the comparison with the press connection used in residential trusses, where many small connections increase shear strength. As I get in there to do the job I'm sure I'll learn more about what could and should be done once I get another good look at things (this week end).
I purchased some 1/4" stainless steel bolts 4" long, to go through the 3" of wood, the 1/4" of aluminum (2 1/8" pieces), the washers, and lock washer, with a little thread left for the nut. There are a couple locations that I think will benefit from a bolt going all the way through to really bond things tight. I also see some benefit from screws part way too, and also some good shear resistance to be gained from glue bonding. At first I was thinking only of bolts going through everything and no glue. That would at least allow disassembly some day.
I'll photograph the process, and I'm really looking forward to getting this behind me. Normally when I do a repair, or when I build anything, it's generally over-built by a wide safety factor.