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Nuts brazed to stuff will work, but you lose the last mm or so of thread due to creep of braze and bolts not being effectively threaded to the end - this becomes a high proportion with small sizes. Having clearance beyond the nut by drilling into the tube allows all the thread to be used.
One (more) possibility is to braze a nut in place, drill through the nut and tube using a core diameter drill, and follow it with a tap to extend the thread.
Regarding a rack for off road use, I made one by cutting and shutting the frame of a garden chair, making use of the existing bends. The bike already had a drilled brake bridge, and at the bottom of the rack stays are short lengths of tube brazed at right angles to accept a stepped sleeve. The biggest issue so far is attaching stuff to it...
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MrE
Just found this thread, awesome!
Love that 90% cut and bend idea. Think I'll have to give that a try on something.
Bracketry is looking like it's gonna be way beyond what I went for which was namely nuts brazed to stuff.
I've been employing my brazing skills(?) to make a wee bit of jewellery lately, want to make something bike related again though. I need a rear rack from my Surly but given that that will need to stand up to off road abuse, not too sure that I'm up to it.