Installed my wonderbar earlier tonight and while I was at it figured I'd slap on some energy greasable sway bar bushings. Except the thing is the holes are not offset such as the stock brackets which seems to be a well known problem. I'm thinking of just elongating the offset hole and using a washer on the bolt. Can anyone think of why this wouldn't be a good idea?

The other question I had on the bushings is that they are for a 31.5mm swaybar bu I have a 32mm. This is such a small difference I can't imagine it causing an issue and the bushings seemed to wrap around the swaybar just fine.

And finally, after I got the wonderbar put on and the stock bushings back on one of the bolt holes for the driver side bracket stripped out. I possibly crossthreaded the bolt but it doesn't look like it. Looks like the threads in the body were rotted out. Since these bolts go straight through and are accessible from the other end, can't I just install a nut and tighten it down vs drilling and tapping the hole?

Yes you can do any and/or all of the above, as necessary.

That .5mm difference is about .019"... about the thickness of a business card plus a sheet of copy paper. None of the parts are that precise anyway, even if unpainted and perfectly clean; it's a case of "measure with micrometer, mark with chalk, cut with axe". Somehow I doubt that it will matter all that much.