John, my DC is the late model HP, have had it on since '04, with 750# & 1000# round bars with no problems with either. I'll try to get some pics if the weather holds up tomorrow.
I find it hard to believe that the new 1200# bars would require frame reinforcement if not for the indentation. My opinion is the paint jamming the bar and putting excessive down force on the cam or jamming for a slight moment and then releasing explosively, pulling at the snap up sharply and bending it at the bottom and pulling the bolt hard against the inside frame, thus the dent.
This new paint is very thick, and comes off in pretty thick (for a paint film) pieces. One time, just for yucks (!!), I used some light grease on the 1K bars to see if there was any difference in feel. Halfway through a 200+ mile trip, dirt and metal dust from the bars and cams built up on the bars and the noise level and snapping in turns increased a great deal. Cleaning off both stopped the roughness and the noise level was almost zero. Thus my case for the paint on old cams being a major culprit in this. I never thought that I should remove or reduce the amount of paint on the bars where they ride on the cams before using. I would ass-ume that a new smooth cam and new bar would work together smoothly and wear in together.
I also understand your reasoning for not using the bolt to pinch against the outside frame, although in a perfect situation (like I'm sure Cequent thinks with the tapping screw!!) there would never be a problem with the idea!! I'll have to decide before Spring what method to mount the snap ups, the damage is minor, no other bending or denting on the left side, and the right has only a mark from the bolt being tightened.
I have been following mrekim's thread, and any thread with DC problems. As I wrote, I have never had any problems with the snap ups, even with the 1000# bars for the last 3+ yrs. His much more severe damage with the associated necessary repairs made me think about other fixes after discovering the problem.
Not meaning to be argumentive, just rambling and thinking out loud!!