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I think it's less the threads, more that bolts are rubbish with handling shear force, especially in fatigue. Which when you cantilever a load on it, will inevitably happen. A single stay can take a lot of this stress, it may be enough to attach the stay even higher to still allow some flex in the rack.
chiroshi-
I wonder if it would work to drill out the block and put a bigger steel bolt, nut and washers in. Or would the shear forces kill any standard bolt? I guess they are not designed to cope with that kind of force so maybe that wouldn't work.
Do the shear forces increase a lot when the bolt gets even slightly loose or are they an issue even when it is bastard tight?
frank9755
No problem!
I'd always assumed the block was steel, but I've just been out to test it with a magnet and it definitely isn't.
Agree that it's asking a lot of aluminium threads.