Are you implying the fixing of the tray to the middle bar caused the problem?
If so, that's definitely a cause for concern!
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Yes
I replaced the brass insert and leg bolt with a M8 stainless bolt and nice big washer. As you know the standard set up is a small bolt that goes into a brass adapter insert, this is because the leg and leg bolt is a standard part that fits all vehicles, the pad under the leg and the brass adapter is what is changed for each vehicle.
What I didn't like is the size of their bolt, and the fact that to remove the bars was a 2 step process - unbolt bar + remove insert before the roof shutter can be closed.
So... with a M8 bolt you just need to drill out the base of the leg and pad - with a thin nut under the pad (keep everything together when you take it off) much easier to fit and remove using a 1/4 inch ratchet drive - which could be seen as a bad thing. If you are worries about security just don't get a standard bolt head.
Bolt length is important - the insert in the car roof obviously has a limited length, and you want to engage all of the thread to ensure it is a strong as possible - the center bar is shorter than the front and back. I can measure bolt length if anyone wants. If memory serves me correctly I cut them to length.