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What a PIA. Good to hear about the structural integrity though. If it was me, I would probably just add a 25-40mm radius to the front leading corner where they tuck into the bullbar, and then take a sanding block and say coarse sandpaper and run along the edge of the flare and break the corner, follow it up with some fine sandpaper for cosmetic effect. I mean you may never get picked up, and if you do I guess worst case is a small fine and take them off - would think they would be more foced on you having the flares to stop the debris flick than the radius on the edges, unless you are going to put it thru an engineering process.
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