I have yet to put more than 10 packs on the car, and so far everything flexes the same as it was when it was installed.
I went to the website where KMC gets their carbon from (KCI), and they have a couple different grades. Obviously, the quasi-isotropic sheets would be the best grade, however, KMC does not specify which the car is made from...this website does also offer lower grade carbon that is in the traditional 90, 90, 90 degree pattern (verses quasiisotropic, which is 90, 45, 0, 90, 45, 0 degree lay)
I would suspect that, based upon what you are describing, the laminated layers are separating at each layer....which seems almost impossible without noticable damage to the edges of the plate....
Anyway, i will be on SolidWorks tonight to design the part (upper deck bulkhead spacer) and will be fabricating it this week at work.
Have you contacted KMC yet Boomerang? Im sure they would love to see what is happeing with their chassis...and I would be pissed if it happened to mine....I would more or less demand a new one if no foul play is obvious...
Boomerang, did you notice any diff gear damage as an issue with the kit? It seems with the flexing at the diff cases that the diff gear would get chewed quickly....
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