The purpose of prototypes is to try everything, and push it until it breaks. In this case, we had a lug failure at high tension. I have never seen a lug built like this before, so there isn’t really anything to look at to benchmark. I can’t say I was surprised by this failure, it was clearly a potential weak point, and dependent on the rigidity of the plate material. The cool thing about making everything locally, is I can quickly create an updated design, have the parts cut, and have them in my hands in a few days.
For the record, this lug is the 9th design iteration, hopefully this does the trick!
As you can see, this design eliminates the center support where it isn’t needed, and replaces it with 2 new supports located close to the tensioning nuts. I think it might even look cooler!