I'm not sure if I'm the only one that encouters this problem, but I keep rounding off the allen wrench hole on the bolts that attach the rack to the bike. This usually happens for the bolts on the front rack because I take that on and off depending on whether I'm touring or commuting. Does anybody know of a place to get higher grade bolts that might not keep doing this? I can always just keep replacing the bolts, but that gets to be a pain.

You must be using a lot of force. Are you sure you aren't cross-threading as well?

I buy stainless metric screws online (fastner-express.com, I think). They work nicely. In a pinch, so does Sears.

I'm really not cranking them down that much, the metal just seems to wear off....

Are you sure they are stainless and not zinc plated?

I use the black steel machine studs that are available in 5mm at a hardware store. Home Depot or Lowes both will have a bin that is full of them. They come in all different lenghts too, which is very handy. The biggest part is the stud head. You won't be stripping them out, I promise. They are not stainless though, so be aware. That means they will probably only last 20 years instead of 40.