So after fully investigating the issues Ive been having, I think its appropriate to post this here.
A little background details for everyone:
I'm currently running the Teraflex 6" LCG LA KIT. I have no problems with the flex both front and rear, and the on road handling has been very mannered. Ive been wheeling this kit w/ 40s for 2 1/2 years now.
Exactly 1 1/2 years into wheeling with this kit, I found a huge FLAW in the design where the upper control arms mount. NO RESPONSIBILTY was taken by TERAFLEX for a flaw aside from saying directions were unclear for the welds, yet a week later Teraflex R&D come out with gussets to help resolve this issue. And here are the gusstes:
Teraflex had this to say:
BINGO. TeraFlex will be working on revised instructions showing how/where these brackets need to be welded.
and here is the original link to the first issue:
After fixing the first issue TERAFLEX did nothing to help me fix any future issues with the other side.
Well low and behold, the other side did break; however, with this break it was easier to understand the DESIGN FLAW. The welds to the frame were 100% fine, but the TERAFLEX BRACKET was not. It is clear as day that the bracket is the WEAK POINT which is why it broke first while the welds to the frame were fine. Those gussets they came out with tie the back end of the bracket to the frame, which might strengthen it a little bit. Nevertheless, since thats not the weak point, people with the gussets could easily still be at risk to breaking the bracket. Since the load of the upper control arm has horizontal distribution the bracket eventually gives and BREAKS at the FOLD. This is then FOLLOWED by the welds breaking at the frame after driving on it for a while or even driving it home from the trail.
Hopefully the pictures can help illustrate what Im saying incase you guys arent with me.
Again, with the bracket completely broken at the FOLD the weight nows resides on the remaining peice which is welded to the JK frame. With the JK frame being so weak, its only a matter of 10-100 miles before the frame gives thus making it appear like the welds were originally flawed. Luckily for me, I was able to see this all happen, step by step, allowing mself and others to see what did break first. To help validate this, I also had a couple other opinions from some shops, techs, and forum members in person, who all explained the same thing happening. (if they want to jump on I'll let them do it themselves) I might be able to take a short video of the load distribution at the bracket to again help eveyone understand this.
And to rule out the specs on my jeep(IE the big tires, weight etc..), please refer to my original fix. People were breaking these brackets with 35s and less than a 1000 miles on them.
I honestly like TERAFLEX as a company, Ive ran 4 of there kits since I was 16 years old, and up until now thought they were solid. Joe has been quite helpful throughout the last 3 years with me, but seems to have dissapeared from JKO altogether.