in both cases the captive bolts for the ARB clamps needed re-tapping
I wondered about this; couldn't you wind in a couple of sacrificial bolts (just far enough that the thread doesn't poke out the other side), then remove them after the galving is done?
Also, one other tip I learned from the guys that galved Tony's rear subby... Sand/grind/shotblast the piece back to bare metal, and then let it sit out in the open air for a couple of days. Turns out that a touch of surface rust actually helps the galv to stick better.