countersinking is when u use a special drill bit to drill out a cone shaped divit where your bolts would go. it's usually used where the head of the bolt goes so that the bolt doesn't stick out, but i think that if u get thick enough aluminum u can drill a hole partway through the aluminum and have the bolts rest in there so they don't get wrecked. the flare ups shouldn't affect the U bolts if u make them right. i don't know how to describe it, but use the cardboard and super glue idea that bigbadscrambler had to make a template. if u can't make it, then u might be able to get someone else to make it for u, but that will probly end up costing as much, or more than, the cost of brand new skidplates.

 

hey ,
does anyone have any dimensions you could e-mail to me.. reason i'm asking is
i work at a sheet metal shop and would be nice and easy to do with some info. ya i could just measure myself but if someone would be so kind as to porvide this info. the i can draw them then punch them out & bend up... i have a 92 lt250r . maybe even make some to sell cheap..

thanks
joe