recently I received a set of 6mil bar spacers from totallyttr. whilst I was fitting them I noticed that the base of each lower bar clamp had " grown " around the clamp stud. this is a common problem when you pull down a bolt or stud that is screwed into aluminium, the thread wants to pull up as you tighten the nuts. I drilled a 12mil hole in a flat aluminium plate, held it in the vice and placed a sheet of emery cloth over it into which I had punched a hole big enough to take the lower bar clamp stud. with the clamp inserted vertically I chucked it in my 1/2" metabo drill and on low speed I rotated the clamp whilst exerting downward pressure on the drill. this cleaned up the clamp base fairly well but I still had to countersink one side of each spacer so that they would sit perfectly flat against the bar clamps. I also placed the stainless washer that normally fits under the locknuts " under " the spacers giving me a total of 8mm spacing. you can then fit a stainless shim washer of say 0.25mm thickness under the locknuts which should be loctited because they will no longer be able to actually mechanically lock onto the studs. so be sure you use HIGH STRENGTH GRADE LOCTITE.
bm steve my install went well, just make sure the bases of your lower clamps are as flat as you can get them, no paint, no thread pullup around the stud base. with the s/s 2mm washers that you removed and placed under the spacers flat side down and using 0.25mm shims under the locknuts you will easily get the nuts on just about flush with the stud end. just make SURE you Loctite them on. one thing I did notice with the spacers was the I.D of the stud hole is so close to the O.D of the stud that when I painted the studs prior to installation they would not fit through the spacers until I had filed them to fit.
