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I'm asking for a specific type of joint for sheet material. Woodworking isn't a best fit, since my question is not limited to plywood. Engineering or DIY seem like too broad a match, I have no hope of getting answers there.

Specifically my question is -- how do I calculate the size of a cutout for such a joint so that a wrench would fit?

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Engineering is a good fit

What you are describing is a part of engineering design. Ensuring there is sufficient clearance is a common engineering problem so they should be able to help.

Disclaimer: I'm not on Engineering.SE but I am a professional engineer.

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