Flanges
Douglas-
I don't see a need to attach the flange to the spar with fasteners. The through bolt will hold the tang and bushing in nicely -- if the through bolt fails keeping that bushing in place will be the least of your worries.
I encourage you to checkout the aluminum/stainless bushing sandwich arrangement I described above. You can purchase this entire tang set/bushing arrangement through Brion for a surprising low price.
For reference, I would say the wall thickness in the bushings is 1/8" and the flange width is about 3/16" to 1/4".
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