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I was also concerned with the distortion of the end-mounted UHMW fairleads as well. The UHMW fairlead I'll be making will be attached top and bottom with multiple bolts and will also fit inside the winch access hole on my front bumper to prevent this. My main concern w/ aluminum is that my fairlead sticks out in front of the bumper and would be the first thing to make contact with a big rock on the trail. Gouging up the aluminum would leave sharp edges that could damage the rope. If your fairlead location is fairly well protected, then aluminum is probably fine.
I've heard that with roller fairleads, you can have problems with the UHMW rope slipping into the gaps between the rollers, since it is not as stiff as the wire rope.
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