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TI FWD XBAR FAILURE
http://www.hobie.com/forums/viewtopic.php?f=75&t=33638
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Author:  stringy [ Wed Jan 12, 2011 1:50 am ]
Post subject:  TI FWD XBAR FAILURE

Ever since I have had the TI I have been aware of a loud creaking/knocking noise on each tack as the mast lean direction changed. After lots of checking and finding no loose parts I put it down to a quirk of the TI. :roll:
Out today in 20knots with sail furled to the first batten, on a tack there was a louder bang than normal and I noticed the mast leaning over way more than normal. Here's why:
Image

The welds have failed and the mast bearing plate has separated from the XBar
Image
Image

We were able to furl the sail by hand (the drum angle was so far out that the furling line did not work), drop the mast and pedal back. The benefits of the Miragedrive! 8)
Hmmm. Hoping this is just a manufacturing defect and not a design problem. :?
At times like this I really miss my local dealer who has been closed since Sept. :(
Have any other TI owners experienced a similar creak/banging noise when tacking and the mast direction changes? It's not something I've experienced with the AI.

Author:  Cowsgomoo [ Wed Jan 12, 2011 1:58 am ]
Post subject:  Re: TI FWD XBAR FAILURE

Mate, that's a worry! :o

Author:  mickeymouse [ Wed Jan 12, 2011 2:47 am ]
Post subject:  Re: TI FWD XBAR FAILURE

Yikes Stringy :o :shock:
I am gob smacked :o :o
It shouldn't be a big deal getting the faulty part replaced but the question remains, is this a manufacturing fault or a design fault :roll: :roll:

Author:  Hammer [ Wed Jan 12, 2011 3:20 am ]
Post subject:  Re: TI FWD XBAR FAILURE

Whoa!!!

Sorry to hear your problems mate. Let's hope it's an isolated problem and not a design issue.

Finger's crossed Hobie sort it out for you.

Author:  mmiller [ Wed Jan 12, 2011 10:04 am ]
Post subject:  Re: TI FWD XBAR FAILURE

This is an extreme load failure which we have seen a few times before. We have already made changes some time ago to the way this is assembled and welded. This corrects any consistency issues with the welding process that may have contributed to this type of failure. The plate now passes through the crossbar and is in contact with the back surface. Should be two welds (outer edges of the plates protrude through the back surface) on the back side of any crossbar with the newer process.

Author:  stringy [ Wed Jan 12, 2011 12:36 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

OK -thanks Matt. I can't recall reading of this problem on the forums. I'm glad Hobie have addressed this issue. I will be visiting my not so local now dealer. :roll:
I'm guessing any replacement crossbar will have the longer plate? I'll be looking out for those tabs for sure.
Was the bang I hear when the mast changes direction related to this? I have been unable to find any loose fittings that may be causing it.
Could you also respond to the cracked rudder issue I posted here.
viewtopic.php?f=69&t=32924&p=133364#p133364
I'd like to know if that type of crack has been seen before?
Or if it could be due to the cleat I added? :?

Author:  NOHUHU [ Wed Jan 12, 2011 2:01 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

Stringy, did you notice any looseness, play or missing screws in the mast V-frame or mast receiver cup? This is the first place I would check after hearing clunking sounds you described.

That plus the glue on the furling drum.

Author:  ainut [ Wed Jan 12, 2011 5:48 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

The same cracking noise was happening to mine the screws on my cross bars were loose I retightend then and it was all good for a while it happened again the last time I went out so this Time I took out the hex screws and dabbed some lock tight on them hopefully this time fixing the problem.
At the same time I tightend the ajusters that are under the screws in the hull.
What looks to have happened to yours, is the side movement has caused the weld to fail

Author:  TxYackMan [ Wed Jan 12, 2011 8:55 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

Woah. I hear creaking sometimes too. I guess dealer will get you a new one?

Author:  Slaughter [ Thu Jan 13, 2011 1:12 am ]
Post subject:  Re: TI FWD XBAR FAILURE

Ouch. Glad Hobie are onto it mate ( as usual ). And the fix sounds like it will now be a pretty strong connection.

Author:  whosyerbob [ Thu Jan 13, 2011 11:05 am ]
Post subject:  Re: TI FWD XBAR FAILURE

Wow! I, too, am gobsmacked. No noises like that on our TI - at least none that I'm aware of...

Author:  Steve Fields [ Thu Jan 13, 2011 3:54 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

stringy wrote:
I will be visiting my not so local now dealer. :roll:
I'm guessing any replacement crossbar will have the longer plate? I'll be looking out for those tabs for sure.


The local dealer contacted us at 9:45 am today (friday 14 Jan). Provided you can give the dealer with all the info that is required for the warranty claim process, we can have a replacement on a truck today. The dealer knows the process and what is required. It is very simple.

This would arrive the same day to the dealer so you will be back on the water this weekend.

Steve Fields
Hobie Cat Australasia PL

Author:  mmiller [ Thu Jan 13, 2011 4:46 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

I have to clarify my post regarding this change in welding process.

This is a change still in process and not yet available on the TI.

To help prevent this failure... It pays to re-tension the crossbar clamps and the bolts that attach it to the mast receiver cup after the first sail, then perhaps every month or so...

The delay in change-over is due to the long lead times for design, purchasing the materials, shipping, processing here, assembly, warehousing, shipping to dealers and distributors... and so on... so, it appears that it will not be actually on a TI for some time as all current stock of crossbars and production is still using the original welded versions.

Again, seems the loose clamps and bolts are the contributing factor. Be sure they are tight.

P.S. The new version will have a weld on the back side that is half the length of the plate and mid plate... not two tabs as I believed was being done.

Author:  chrisj [ Thu Jan 13, 2011 5:36 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

Gee Stringy, you're doing better than I could. I rang one of the Sydney dealers two days ago about my aka problem. They said they would get someone who knew about Hobies to ring me back and so far, no call.
Did you deal with the more Northerly or the more Southerly of the Sydney dealers?
Ah Kevin, how we miss you. :cry:

Author:  Steve Fields [ Thu Jan 13, 2011 5:43 pm ]
Post subject:  Re: TI FWD XBAR FAILURE

chrisj wrote:
Gee Stringy, you're doing better than I could. I rang one of the Sydney dealers two days ago about my aka problem. They said they would get someone who knew about Hobies to ring me back and so far, no call.
Did you deal with the more Northerly or the more Southerly of the Sydney dealers?
Ah Kevin, how we miss you. :cry:


Just PM'ed you.
Best,
Steve

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