Racer X Aluminum Front LCA, Potential Failure

[Jeff@Racer X Fab]

On February 21st, 2017 at 7pm EST we were informed of a possible failure that involved our aluminum front lower control arms. The failure happened on a highway in the state of Washington, luckily the customer is safe and was not hurt during the incident. The vehicle damage appears to be the front fascia, front right fender, and plastic lining. From the initial pictures, it appears that impact was the cause of damage, from a pothole or abrupt change in concrete elevation. The specific area of the failure is the urethane bushing cup that connects to the chromoly caster arm. Again, from the picture it appears to be a failure at the threaded portion and not the weld. We will not know the complete cause of the failure until the control arms are returned to us for inspection.





On February 22nd, 2017 at 10am EST we held a meeting for corrective action. We decided to immediately pull the urethane option for the aluminum front lower control arms until further notice. Urethane bushing cups were pulled from inventory and quarantined. We looked up every customer invoice since product release and started the process of updating their control arms with replacement components (rod ends). Emails to be sent to all customers using urethane option beginning February 24th.

On February 23rd, 2017 at 10am EST we began investigating the reason for this potential failure mode. In our opinion the failure was caused from impact.

Why did the urethane bushing cup fail from impact?
We believe the failure happened due to the root of the thread being cut too deep at the neck of the component causing a stress riser.

Why was the threading cut too deep?
The tool insert was changed and the correct tool length offset was not updated.

Why was the tool length offset not updated?
No log or procedure for TLO once new insert is installed.

Corrective action: All tooling now to have logs, change procedure to account for correct tool length offset.



For our customers that have the aluminum front lower control arms with urethane bushing cups, please inspect your control arms for any areas of potential fracture. Specifically, around the neck of the caster arm bushing cup. We will be sending chromoly rod ends next week. In addition, we will be offering a $50.00 cash voucher for our customers that provide us with an alignment receipt after they have received their replacement components.

We hope to have the control arms returned to us soon for complete inspection. For our customers, we hope you bear with us and we apologize for any inconveniences this may cause. We are open to any questions, comments, concerns or criticisms.

[twag4]

I am a knucklehead, but will the polyurethane still be an option? If so when will it be available?

[bcj]

Thanks for standing up for this and handling it with alacrity.

[chezzy79]

I am the owner of the car involved in the accident, and I just want to say that Racer X has been on top of it and the fact that they took the initiative to make this post really speaks about their integrity.

I will work with a reputable local shop and Racer X to send the parts back for analysis, and if anybody has any question about the breakage, how it happened, my driving habits, etc., please do not hesitate to ask me. The affected parts were purchased new and installed professionally in late September 2016.

Also, I posted a question a few days ago about the durability of the parts posing as an interested customer, since I'm no expert in the matter, but please disregard that thread.

[kch]

Super impressed at the response. Well done.

[Captain Snooze]

This is the proper way to handle an incident like this. Many kudos to RacerX.

[Tokay444]

You may also want to consider switching to a J thread for a larger root radius to lessen the chance of sheering.

[Shankenstein]

I'm sure the automotive guys have already recognized it... but RacerX is illustrating the 8D process (a proven method for solving problems). Identify the problem, contain it, assess the root cause(s), determine corrective action(s), and minimize the risk of recurrence in the future (and on similar products).

Mad respect for the transparency and proper handling of the issue. This is one of the many reasons why our community supports RacerX Fabrication.

[xkalelx]

Your internal Corrective Action Request has just won me over as a potential customer. Will inquire in the near future for FLCAs. Cheers to your professionalism.

[jamal]

Claming it was from impact while replacing all the poly with rod ends seems a bit contradictory?

Those bushings are putting a bending load on the tie rod whenever the arm is not completely level. From the pictures fatigue seems more like the cause.