I just trimmed mine. As long as you leave the nut on before you cut it you should not have a problem. When you remove the nut it takes care of the burr.
I did that for the rear; again, those are on, but I had to use one bolt from the front kit because the thread was not long enough. I left the bolts a bit long so that I can ise them to bolt on a bump stop extenion on top of the rear axle so that the rear suspension does not hit the body like it has in the past at max flex.
Also I needed to grind the corner of the plate a fair amount so the shock body would not be dented. Be sure to check your clearance.
Where did you have problems? Front or rear?
did you measure the threads and round? just wondering if they are the same (thread larger diameter) as the ones i have.
No; I am currently in Panama, and the Jeep is in Costa Rica...