I do not see this happening to the chassis itself....after looking at the car for awhile and trying to decipher how this could happen, i come to realize one huge problem with the design.
Each top plate screws to the center aluminum bulkhead and spans to the rear bulkhead and front bulkhead where two screws are also used....included in the conversion kit are two aluminum spacers that raise the mounting position up to that of the center slipper bulkhead. The rear and front screws, however, are screwing into the plastic camber plate that sits on the diff halves. While this is the stock location of the standard top plate mounting scews one significant difference is present. On the stock top plate, the design is such that it notches into the mounting location whereas the KMC top plate creates a 5mm moment arm centered at the thin section of the camber plate mounting location.....
This all means that as you drive the car, the area where the rear and front top plate mounting screws thread into the camber plate will become weak as the car flexes (and cant flex the chassis before those areas give-way)....
This being said, I believe that I will be designing and machining the correct spacer for this design...one which will notch into the rear and front top diff halves.....
If you look at the KMC chassis in the original pics, you can see that they were running the car with an aluminum front tower mount and this camber brace all machined into one unit.....this would definitely make a difference in the amount of stress this moment arm produces.
food for thought....and I dont think your chassis is failing....check this area of the car and let us know if I am onto something here.
I do have the chassis by the way and have held onto it and tried to bend it while all put together....the top plate diff mounting screws flex WAY before the lower chassis plate.
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