mrfixit, I have a friend who had the same problem as you. We fixed it by lining the inside of the scupper with a piece of steel conduit. It was a snug fit and I also flared the inboard end of the insert so that it would just sit level with the deck. We then took some marine goop, liberally smeared the exterior of the scupper tubes inside the hull, (especially in the area of the stress fracture), take a piece of rubber garden hose, slit it lengthwise wrap it around the exterior of the scupper tubes and clamp tight with two stainless steel strap, hose clamps. He has never had a leak since (3 years) I lined the scupper holes with the metal pipe and have never had a leak caused by the cart causing the scuppers to flex. The cart still fits in the scupper tubes but they never fail now. I know my chum carries a lot of weight in his hull and has never had a problem since we reinforced his scuppers. From what I can understand, Hobie has acknowledged, and actually fixed, their design fault/scupper problem. They too, reinforced them during the manufacturing process. I suspect you will have to do as we have done because your hull guarantee has long expired. It is not a really difficult fix. Good luck.
Regards.
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