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I believe you need to make a clear distinction between the Danny Gray production seats and the Danny Gray custom seats. Sorry to hear about your problems and the frustration it has caused you.
For the Rocker Danny Gray only has one seat model the Weekday Solo, its the same used for the production models and custom seat program I confirmed this over the phone with Sherry. The seat I have is the correct part number for the Rocker.
Some forum members have taken the seat out of the box and bolted it on the Rocker with no problems other members have stripped threads or bent the crap out of the mounting tabs to get there seats to fit. It all comes down to Quality Control, not every seat they make is the same.
If I fix the thread I will have the Danny Gray on my bike because I like the style of the seat, but I wish the seat would have just bolted on instead of having to modify the mounting brackets by redrilling them to get a decent fit (its still not a great fit).
I went with "Bitchin Seats",...they custom make them according to your height and weight. I was concerned about it riding like a rigid, so they added extra back support to the seat. I do feel the bumps more than with the Rocker C stock seat, but not significantly. It took a couple hours to get use to, but I love the way it corners now, and I can ride all day without getting a back ache. Seat height is about 23", and I now I can be flat foot easily, and not on my toes. Seat also covers the bracket holes in the frame, and installs in about 5 minutes. (not counting getting the clunky stock seat off).
From: Northern Calif.. No not SF... I mean Northern Calif!!!
I did something similar to a off road bike i had. It was a bit different but it was a chain tensioner bolt hole. It striped, I drilled and broke a bit and thought about it a bit and loaded it in the truck and took it to a machine shop. I didnt want to at first because I was thinking of what he would think when he saw my mess "dam" what did this guy do here. Anyway the guy was a perfectionist and when he was done - some welding and "heli coil" you could not tell it from the other side.
I would suggest you take it to someone that works on metal as an art and you'd be amazed, maybe even show them the seat and the brackets. I know its more money but I'd hate to think what could happen with the jbweld if you really needed a bolt to "Stay" in the new hole your about to make, if it's a dead hole now, i guess no big deal then.
damn dude, i feel bad. i recommended the seat to you. mine went on with very little adjustment to the brackets. i feel bad for ya man, i know the feeling of being discouraged and not even wanting to look at the bike cause you are so disgusted, i had the same feeling when i went through the struggle with my front wheel.
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