First off, I apologize for these initially not fitting. I really wish we could have rectified it right there in our normal way (getting your product back, evaluating the fitting issue, send a new proper one back) because that not only makes sure that any quality control, shipping damage, or other issues that may arise get taken care of, but that in the end you get a product that installs properly, as that is the way we test our products around here.
I know that you and I talked about the welding issue, I said that the structure of our sliders would be fine welded to your Jeep, I also apologized and tried to make things right with you. You've been nothing if not level headed and honest with me and this forum, and that is refreshing and appreciated. I hope I have been the same with you.
So on to what happened, and for that I have no idea. The dent in the tube (1.75 x .120 wall for those curious) is an indicator of the amount of force we are dealing with, but the rockers of an XJ can take a lot of abuse and still be structurally sound (albeit dented to hell,) so why did the damage on your Jeep occur? Without testing and/or being there I can only pose questions.
- Was the bulk of the slider touching your rocker down the whole side? Or was it only affixed at the top with weld? This would put tons of pressure on that weld edge alone until the rest of the slider made contact with the body.
- Was this attachment point (just the weld) in a location that more easily put leverage on that portion of the rocker than being bolted to the side?
- Did the heat from the weld cause an issue with the sheet metal, with a seam, or with some panel glue?
- In what way is this install different than welding box tube into the rocker directly. Leverage on the step? Resistance to twisting of the box tube because it's welded on the bottom too?
I'm sorry I've got more questions that answers. I do know that I've used and tested the ones on our shop XJ as intended (and not as intended, projects around my house get weird...), and we do have others that have used them as protection with no issues. That doesn't mean I think your wrong, I just wonder if this was related to the installation, the sun and the moon aligning that day, or a legit weakness in our product.
I've got another e-mail coming your way today, where we can talk about making it right between us privately.
If anyone has any questions or issues about or with our products, please feel free to contact me daryl at jcroffroad dot com
~Daryl
