Rob,
I have sent you a couple PMs about this problem but no reply. You can see my first post from 03-15-2012.
I was doing the final install on my rack kit today and I’m having problem with the fit of the aluminum clamp. With the aluminum clamp tourqed and the rubber in-between it and the rack is not tight. I can jiggle the rack with the clamp fully tourqed. I have one of the first kits. The aluminum is bore too big or the rubber is not thick enough?