As I recall, that loose mast pin problem has been around for awhile with the AI's too. Always good to inspect it prior to mast penetration.

BTW, we had a TI Xbar failure out here just last week.

Thanks to Stringy, SunE and everyone who is raising awareness and providing feedback.

That sure looks like Aluminum oxide corrosion starting under the corners...

I gave the replaced TI x-bar a thorough inspection with a magnifying lens and took some macro shots. I'm pleased to report that with over a year of use the welds look OK with no visible cracking. So it seems the initial cracks may well have been from a welding/production issue. This is not the reinforced x-bar.

By way of comparison this is the x-bar from my 09 AI.

I did notice that the socket screw had backed out a little. I didn't take a pic before I'd tightened it but there was a gap between the two nuts of a bit more than a full turn. It seems the socket screw is backing out of the molded in brass hull fitting even with the extra lock nut. I didn't use locktite on this screw as I was concerned it would make removal very difficult if I had another breakage. The good news is that the newer material socket screw is holding up well. I removed it and it was still straight. This is an area that needs regular inspection for looseness. The crossbar bolts/ V-Brace nuts were all still tight.

kayakman7
If everything was tight that's good to know.

At this point I don't believe we have a definitive explanation as to what exactly causes the weld on the bearing plate to break. Hobie has since corrected this problem with their new design and that's what is most important.

What I've been trying to establish is how the average person can determine beforehand, if their old style crossbar is about to fail. I should think Hobie would be interested to have your crossbar to see if this "grey line" is actually a crack in the weld or not.

However, you did not break it by sailing it; it broke because somethings wrong, it's not your fault. As for "which conditions are too much..." I believe the general rule of thumb is when one begins to see the whole ama a couple of inches under water. It's also been well discussed about the benefit of when to reef your sail. Again, I wish for all of us to be as safe as possible on the water and proactive through these continuing discussions.

the metal begins to fail, progressively getting weaker, and at an increasing rate, till it fails completely.,.. every second we sail, every wave we hit, every minute change in wind, is another cycle on that weld, another step towards it's failure.
Cheers, J

Sun E,

the failed XBAR was on a 1 yr old TI. Owner heard few noises, thought the clearance on the bearing ring seemed odd and later discovered some looseness in the XBAR collars.

Cheers?!?

That corks it. I'm gonna put this AI sukka on E-Bay!