[quote=Dogboy]1/2 x 1/2 stock (or round bar) would only leave 1/16” wall thickness after tapping for the 3/8” dia bolt, so I think it would still be a problem. Or at least, not provide any additional strength over the nut.
One thing you can do is purchase “extra wide” nuts. They are beefier than a standard hex nut and the extra width also prevents them from turning inside the anchor plate, so you can tighten the crossbar bolts more easily since you don’t need to hold the nut with a pair of vice grips to prevent it from spinning. Install with blue loctite so they don’t loosen up.
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