This details the gap problem I had with my GIVI SR357 rack and how to correct it - and what to do if you already took it too far like I did.
https://twowheelobsession.com/2014/10/09/givi-sr357-quality-control-issue-fix/
Man... I get that you like to make videos, but 5 minutes of gabbing about something that could be covered with about two paragraphs is a bit much.
This serious "Quality Control" issue that you say you've just discovered
has been talked about quite a bit on the forum already. Many other folks have discovered the same misalignment, so I do not think it is just a matter of them sending you the wrong spacer.
Some folks are just tightening up the rear 3 bolts first, and then doing the two front most bolts afterwards to apply tension to the rack. They believe that GIVI intentionally has made the rack where it will be under torsion to improve the weight carrying capability of the rear subframe.
I also stuck a washer in (just one) but put mine underneath the spacer so it wouldn't be visible. And my bolt seemed to be plenty long enough even with the washer, so I don't really think that was the reason you buggered your threads. Sounds to me like maybe you just got it cross threaded.
The problem with that (type of) rack is that it places all of the weight of your trunk, and anything that you put into it, on the stock (plastic) luggage rack, which (working from memory here) is only rated to carry about 5 or 8 lbs. The case itself weighs most of that. If you overload that rack you will crack the cast alloy subframe underneath that was only designed to carry the weight of the rear shrouds and fender, hence the low weight rating of the rack.
Installing a Givi SR rack, quality control problems and all, will reinforce that pot metal subframe with steel pipes and increase the load capacity greatly.
Yes. Griff has the optional lights in his trunk, and Givi makes a quick disconnect lighting setup so you don't have to manually connect and disconnect the wires.
A possible solution for you, Griff, may be to do the security pin mod I have done on mine. I don't have the lights, just installed the pin for, well... security. It does tend to hold things a bit steadier than just the spring loaded latch does. If you used a nut and bolt in lieu of the clevis pin you could snug it down as tight as you wanted.
Since I mounted my security pin exactly where your light contacts are located you'd have to do yours on the other side.
Linky