Holy cow, I thought I was the only one that did that!
Mine has not broken yet. My bike is a June 2004 build, which most people refer to as a "2005" in the US. So, I order the BDCW bracket for a 2005, and it didn't fit just like your bike. I also carved into the bracket to make it fit. After I'd done that I e-mailed BDCW, and Keith said he would take the carved bracket back and send me the right bracket for a 2004 that was cut to fit the old frame that had the extra gussets. I felt bad about essentially sending him a part that I
screwed up, so I said I would just run the thing until it broke. He actually pleaded with me to take it off because he was afraid of what would happen if the thing broke while the bike was loaded. Great people at BDCW.
Another option would be to go with the CJ Designs mod: http://www.cjdesignsllc.com/products...ation-bracket/
Weld86 makes one as well, but I don't know how well it works. It looks like it just strengthens the stock mount rather than removing the bolts from the engine: http://www.weld86motoparts.com/KTM-950-990-ADV.html