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I had ZERO fin rod failures and never saw rust on rod stress points prior to the availability of ST Turbo fins. The problems started when I bought the ST Turbo fins.
Rnykster, you just solved your own problem!
If the smaller fins have never given you a problem, that's your solution! Try the ST fins. They use the old rods that have never given you any issues.
You compare your kayaking activities to that of a distance runner and not a sprinter, so consider the Standard fins to be just like regular sneakers, the ST fins to be high performance marathon running shoes, and the ST Turbo fins to be track spikes. Clearly the track spikes are the fastest, but no marathon runner in the world wears track spikes, sure they're lightweight, but they're not built to do the job that a marathon runner needs to do.
You don't see marathon runner's complaining to Nike that they should be making better track spikes so that those runners can wear them for their races. You don't see Nike having to tell users that they can't use track spikes for marathons. Clearly it's up to the user to decide what works for them.
If you decide to roll the dice in one of your next races and use ST Turbo fins, then you'll have to be prepared for the potential of failure. If you don't want a failure, and you already know that the ST fins never give you a problem, and haven't failed even once, then you have the option to run those.
Looking at the fins in this way also clearly eliminates your argument that Hobie doesn't offer you performance pieces in the same way that a bicycle manufacturer does.
Let's face the facts, these boats weren't purpose built for racing. If they were, they'd be about 20% lighter, and have less comfort and convenience features. Your use is an extreme use for these boats, and it sounds like the performance fins (the ST's) have worked perfectly for you.
It's up to the user to understand what works for them. I've been able to use the ST Turbo's for several extended high speed runs without a single failure. Clearly if I entered a race, I'd try to use those fins. You might have another decision to make.
So clearly Matt Miller and the Hobie staff have heard your complaints. As Matt stated, they made changes to their process directly because of this thread. Now it's your turn to accept responsibility for your own use, and go out and enjoy your boat. My advice, give those ST's another shot. They seem perfect for your use. If you're not able to break records with those fins, then you may want to consider another pedal boat, or perhaps you'll have to look at the guy pushing those pedals and accept that maybe you're not the guy to break that record. Hey. We can't all be record holders!