I have a 50" light bar that I need to fix. The end cap where the bolt screws into cracked a piece off. I have a friend with a drill press and was figuring on drilling and tapping through for a bigger bolt and was in need of any pointers or help on doing it & if there's a way to make a hole to fit the bolt head so it doesn't turn when I tighten down the nut from the opposite side of the bracket.

 

I have one also. I have seen one guy that got a bolt in from the inside out as a stud. Mine did not have any room on the inside for the head so I just drilled and tapped it.
When I was mounting it to the jeep the drivers side started to strip threads so I stopped. Added a few zip ties just in case it pulled out later.
I'm going to get some different mounts and when I do that I'm going to heli-coil them to fix the threads and I was thinking of using a long set screw and a nut on the outside. Figure I could put the caps back on the bar, then put an asston of red lock tight on a set screw and run it in until it bottoms out. Let dry and then mount back onto the jeep with a lock nut.

 

The bolt head is too big. Does anyone have any help or other options I can do?