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Re: [adatesman] SAFETY ALERT- MORE ALIEN FAILURES
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sungam


May 22, 2009, 10:57 PM
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Re: [k.l.k] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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k.l.k wrote:
angry wrote:
A few alien threads back, I posted an analogy that's right on. Imagine that for the same price, you can buy a new Porsche or a Camry. The caveat is that you have to test the brakes on the Porsche yourself as they could catastrophically fail. Of course if they fail the test, they will send you a new Porsche that you'll again have to test the brakes on.

So do you get the slow economical car that you'll never have to worry about maintenance on or do you go for legendary performance but accept that you'll need to be a more hands on owner? Neither decision is more correct, those are just your choices.

This analogy is almost perfect. It needs only one small change:

You have to test the Porsche's brakes while running at triple digits mid-way down the Furka Pass.
I would say it's more like going an unknown speed, as you could whip-test them or bounce test the shit out of them in a safe environment, but you wouldn't know WTF forces it's holding.
Unless you have access to a brake testing facility, which are hard to come by.


donald949


May 22, 2009, 11:01 PM
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Re: [angry] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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angry wrote:
Just to clarify, even though you can't pinpoint Laramie, you're still thinking that Sogdiana is from CCH?

Other than the writing style is there more evidence? I only ask because most eastern block euros write the same.

A few alien threads back, I posted an analogy that's right on. Imagine that for the same price, you can buy a new Porsche or a Camry. The caveat is that you have to test the brakes on the Porsche yourself as they could catastrophically fail. Of course if they fail the test, they will send you a new Porsche that you'll again have to test the brakes on.

So do you get the slow economical car that you'll never have to worry about maintenance on or do you go for legendary performance but accept that you'll need to be a more hands on owner? Neither decision is more correct, those are just your choices.
Good analogy on several fronts.
Brakes/Pro being life saving equipment.
But I would add:
Porshe verses Vette verses Mustang.
Some are good with the Vette or Mustang, while others have to have the Porsche. And of course the owners of each will argue to the death about their choice.
:D


curt


May 22, 2009, 11:04 PM
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Re: [healyje] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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healyje wrote:
Maybe we should take stock for a moment given this has been going on for years now. So, here's a list of problems that have gotten by CCH's best QC efforts and shipped to us:

- Misdrilled Axle Holes
- Unswaged Stem Loops
- Size Color Coded Wrong
- Inconsistent Cam Lobe Hardness
- Missing Axle Washers
- Failing Axles
- Quenched Brazes
- Incomplete Brazes
- Bad 'Tensile Tested' Cams

And let's be straight up front - shit happens and things go wrong in manufacturing - it's unavoidable. The name of the game is to not let bad parts get further down the line and not shipping bad finished goods out the door. And there are multiple straightforward QC solutions for each of the problems listed above that would prevent goods exhibiting any of these problems from shipping. Those solutions aren't rocket science and CCH's enduring inability to successfully [and openly] institute these measures over the course of several years means the real problem is cultural and lies at the feet of the owner.

The issues we have been faced with since the beginning of this saga are fourfold. First, for every bad cam we discover and post up about, you can bet your ass there are X number of similarly bad aliens still out there either sitting on a store shelf or hanging on someone's rack waiting to be discovered. Second, we now know that there are variously bad Aliens shipped both prior to and after the recall. Third, in all likelyhood CCH is still incapable of preventing bad goods from shipping perpetuating the problem. The fourth, and most telling, is that CCH and Dave's ability to communicate remain immovably unchanged; it is still steeped in silence, lack of openess, defensiveness, denial, and accusation.

Taken together they paint a grim picture of a situation unlikely to change in any significant way and that an unknown percentage of Aliens shipped by CCH in any given year will be bad in one way or another. It should also be noted that these sad realities exist despite of the best efforts of any number of highly experienced people in and out of the climbing gear industry's best efforts to help CCH out with advice, assistance, and even offers to buy them out. To-date, all such efforts have failed for a variety of reasons.

Many of us appreciate what CCH brought to the table with Aliens and love many aspects of the design. But to those of you who can't simultaneously manage the duality of loving leading on Aliens on one hand and acknowledging the obvious malignancy inherent in their manufacture, I would say it's no different than any other aspect of climbing - we are all responsible for recognizing, acknowledging, evaluating, and taking risks - the name of the game is doing so wisely and with your eyes open.

At this point anyone who is operating in blind denial because 'I love my Aliens' is a fool and incompetent in my book and I wouldn't climb with you. Want to buy or keep climbing on Aliens? Cool - but then it's on you to ensure every one is competently tested by yourself or anyone but CCH whose 'Tensile Tested' test mark has been proven untrustworthy.

The only sure thing thing you can say about Aliens at this point is there are still a lot of time bombs out there and this won't be the last word or thread on bad Aliens on RC.com - this beat will, unfortunately, go on...

Some people still love to drive their Corvairs too, in spite of everything Nader uncovered. Cool Go figure.

Curt


Partner angry


May 22, 2009, 11:09 PM
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Re: [donald949] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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The reason I went with the Porsche vs. Camry is that we aren't comparing super high performance and legendary cars here.

We've got the Aliens that are hands down superior to everything out there by multiple factors. We've got the metolius/C3/zeros that work, they're reliable, and are quite adequate at picking up the groceries.

I believe that Aliens (that don't break) are actually that much better than the competition. Of course, it's that "don't break" part that seems to be giving us all trouble.


adatesman


May 22, 2009, 11:50 PM
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altelis


May 23, 2009, 12:17 AM
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Re: [sungam] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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sungam wrote:
k.l.k wrote:
angry wrote:
A few alien threads back, I posted an analogy that's right on. Imagine that for the same price, you can buy a new Porsche or a Camry. The caveat is that you have to test the brakes on the Porsche yourself as they could catastrophically fail. Of course if they fail the test, they will send you a new Porsche that you'll again have to test the brakes on.

So do you get the slow economical car that you'll never have to worry about maintenance on or do you go for legendary performance but accept that you'll need to be a more hands on owner? Neither decision is more correct, those are just your choices.

This analogy is almost perfect. It needs only one small change:

You have to test the Porsche's brakes while running at triple digits mid-way down the Furka Pass.
I would say it's more like going an unknown speed, as you could whip-test them or bounce test the shit out of them in a safe environment, but you wouldn't know WTF forces it's holding.
Unless you have access to a brake testing facility, which are hard to come by.

Its actually not that difficult to set up a drop test for your aliens using a fuse to gauge whether the cam held an appropriate amount of force.


Partner angry


May 23, 2009, 12:23 AM
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Re: [adatesman] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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I saw that a while back and responded. I'm sure it got buried.

No, I have no idea what type of machines they used. This was 1999 or 2000


adatesman


May 23, 2009, 12:24 AM
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sungam


May 23, 2009, 12:28 AM
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Re: [altelis] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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altelis wrote:
sungam wrote:
k.l.k wrote:
angry wrote:
A few alien threads back, I posted an analogy that's right on. Imagine that for the same price, you can buy a new Porsche or a Camry. The caveat is that you have to test the brakes on the Porsche yourself as they could catastrophically fail. Of course if they fail the test, they will send you a new Porsche that you'll again have to test the brakes on.

So do you get the slow economical car that you'll never have to worry about maintenance on or do you go for legendary performance but accept that you'll need to be a more hands on owner? Neither decision is more correct, those are just your choices.

This analogy is almost perfect. It needs only one small change:

You have to test the Porsche's brakes while running at triple digits mid-way down the Furka Pass.
I would say it's more like going an unknown speed, as you could whip-test them or bounce test the shit out of them in a safe environment, but you wouldn't know WTF forces it's holding.
Unless you have access to a brake testing facility, which are hard to come by.

Its actually not that difficult to set up a drop test for your aliens using a fuse to gauge whether the cam held an appropriate amount of force.
Do explain how this is done, me and several others are interested in performing some tests (perhaps in a different thread).


altelis


May 23, 2009, 12:29 AM
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adatesman wrote:
altelis wrote:
Its actually not that difficult to set up a drop test for your aliens using a fuse to gauge whether the cam held an appropriate amount of force.

Not all that difficult, but not all that accurate either. Lots of variation in the breaking strength of cord depending on the knot used, how it was dressed, which manufacturer, etc. But its cheap and fairly straight forward.

This was the topic of a very long discussion over the weekend between myself and someone at one of the gear companies over the weekend and I've got a more repeatable way to do it that shouldn't be too expensive, and depending on how this all shakes out I may see about getting a bunch made for whoever wants them.

Yea, thats exactly right. For me, when I was debating doing it, it was about being able to estimate, to a close enough approximation, the breaking strength of the fuse. I was looking for an acceptable minimum as opposed to a reliable maximum. If that makes sense.....

Didn't end up doing it as I only have 1 alien, that I've aided on and bounce tested all to hell as I was learning and feel satisfied it'll hold. I was going to then test a bunch of aliens I was planning on buying, but somehow ran out of money. Fucking Georgetown and DC are really, really, really, expensive......Unsure


adatesman


May 23, 2009, 12:39 AM
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altelis


May 23, 2009, 12:43 AM
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Re: [sungam] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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sungam wrote:
altelis wrote:
sungam wrote:
k.l.k wrote:
angry wrote:
A few alien threads back, I posted an analogy that's right on. Imagine that for the same price, you can buy a new Porsche or a Camry. The caveat is that you have to test the brakes on the Porsche yourself as they could catastrophically fail. Of course if they fail the test, they will send you a new Porsche that you'll again have to test the brakes on.

So do you get the slow economical car that you'll never have to worry about maintenance on or do you go for legendary performance but accept that you'll need to be a more hands on owner? Neither decision is more correct, those are just your choices.

This analogy is almost perfect. It needs only one small change:

You have to test the Porsche's brakes while running at triple digits mid-way down the Furka Pass.
I would say it's more like going an unknown speed, as you could whip-test them or bounce test the shit out of them in a safe environment, but you wouldn't know WTF forces it's holding.
Unless you have access to a brake testing facility, which are hard to come by.

Its actually not that difficult to set up a drop test for your aliens using a fuse to gauge whether the cam held an appropriate amount of force.
Do explain how this is done, me and several others are interested in performing some tests (perhaps in a different thread).

PM sent.....I didn't feel like starting a thread, etc. But if you feel like making the contents of the message public, feel free.


Rudmin


May 23, 2009, 1:10 AM
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adatesman wrote:
sungam wrote:
Do explain how this is done, me and several others are interested in performing some tests (perhaps in a different thread).

Easy enough to explain, so I'll just do it here.

1. Find small diameter rated cord of your choice, basing the decision on its rated breaking strength and the % loss from your knot of choice.

2. Cut a length of the cord, tie loop knot on either end. You'll be essentially using it as a mechanical fuse. Note: you're not tying a circle, you want 2 loops with a straight bit between them.

3. Place gear in bomber placement.

4. Clip biner to gear, first loop to first biner, another biner to the other loop.

5. Attach a length of something fairly static to the second biner.

6. Attach something heavy to the other end of the static thing.

7. Huck static thing off cliff and stand back.

8. Hope you didn't hurt someone, retrieve your static thing and biner, wash, rince, repeat with other gear.

As I mentioned, its not all that exact since manufactures rate their cords differently and there's variation in the breaking strength of the knots depending on what you use and how you dress it, but it will get you in the ballpark. The things I'm thinking of making should be repeatable within +/- .1kN, but its a question of whether there'll be enough demand for them for me to bother with getting them made.

-a.

To get an estimate of the force, you could take some really tiny cord or even string and find the breaking strength of a single strand or single loop of it (when clipped and tied the same way as in your drop test) using a known mass such as a bucket of water. Several tests should give you a pretty accurate number. Loop it several times to multiply that strength up to what you want the fuse to be and try to equalize all the strands as best you can before you test it.


rocknice2


May 23, 2009, 4:14 AM
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adatesman wrote:
Replying to Angry because he's at the bottom of the list. (BTW, did you see my question about what machines CCH were running? I'm curious if they're Mori Seiki.)



I assume your talking about what machine is used to make this head.
Well what difference does it make if they're using a Mori Seiki, Haas or any other CNC machine.
You mentioned a 5 axis CNC in an earlier post. This part is clearly in no need of a 5 axis operation.

There are two good ways of making this part:
#1. Use a 3 axis CNC turning center with mill capability. A simple deburring of the tip left by the part-off tool is all that is needed.
Pros- High precision part in reference to the two mill surfaces and the cross hole.
Cons- Expensive machine, longer cycle time.

#2. Use a 2 axis CNC turning center and a separate CNC milling center. 1st op is turning of part with a deburring of tip. 2nd op is milling one side of the part. 3rd op is milling second side and cross dilling the hole. If nesting numerous parts together then the cycle times drop dramatically.
Pros- cheaper to buy 2 simple CNC machines. More production per hour[splitting the ops]
Cons- Somewhat less precision but can still hold +/- .0025"


There is a third option of using a twin chuck 5 axis with milling cap. but this type of machine is just way too expensive


One last point, I don't see why they won't make a drainage hole for the brazing process.
I can't see a .040" hole making the head any weaker especially after it's filled. It doesn't seem as though the head is the weakest link.
In a perfect cam I would think it's the axle/lobes that would fail.
In reality it's the joint that is made a person and not easily verified that seems to be the villan in this case. This braze can be strong as an ox or as weak as a kitten.


Partner cracklover


May 23, 2009, 4:18 AM
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Several years ago I did essentially exactly what Adatesman suggest for all my (and several partners) Aliens. I have explained it online (perhaps how Aric got the idea).

Here's some video for anyone who's curious.

http://www.youtube.com/watch?v=jMeGtWjmS54

Cheers,

GO


Partner cracklover


May 23, 2009, 4:24 AM
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Re: [Tipton] SAFETY ALERT- MORE ALIEN FAILURES [In reply to]
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Tipton wrote:
Cracklover, sorry for not getting back sooner. The reason for you having to buy me two sets is because I was going to front the cash for the initial set of new aliens.

If you want to split the cost of the aliens with me, I will accept only one set of micro cams after I win.

If you're still game I will Paypal the cash to Aric tonight.

They need to be new, varying sizes, and five of them total. If any one of them receives considerable damage (I'll overlook minor lobe damage) prior to the rated strength, I win.

Let me know,

Tipton

I'm game with splitting the cost of the tested cams.

But at least one has to fail at under the rated strength, not just "receive considerable damage".

GO


notapplicable


May 23, 2009, 4:54 AM
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rocknice2 wrote:
I'd be willing to cough up dough. $20.
I'll send in $50. if we expand this to 5 BD and 5 Metolius cams too.
Thats about 90 members @ $10. each to buy 15 cams

Choosing the 5 worst looking cams off a store wall is not a bad idea seeing as we are using such a small batch to test.

I've got $20 on it but I'd rather we tested as many aliens as possible as opposed a variety of manufacturers. While I would like to see a bunch for each broken, right now I am far more interested in seeing how many aliens fail below spec and seeing every single one of the heads opened up for a visual inspection of the braze.

That is just my opinion though. The $20 is available for the tests either way.


healyje


May 23, 2009, 4:55 AM
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I'll donate four barely used late '04 / early '05 undimpled hybrids to the game...


notapplicable


May 23, 2009, 5:08 AM
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Aric

If you already have a paypal account set up and if I understand it's function properly, you shouldn't have to do much but buy the cams after the money is place. Obviously if you don't want to deal with it someone else could collect the funds and buy the cams online and have them shipped straight to you.

What ever your comfortable with works for me but it sounds like we can pool enough funds to do a decent test. If performing the pulls is not too much of an imposition I think it's a good idea.


(This post was edited by notapplicable on May 23, 2009, 5:21 AM)


Partner mr8615


May 23, 2009, 5:11 AM
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You'll get 10 or 20 from me if this thing goes down.


adatesman


May 23, 2009, 1:32 PM
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rocknice2


May 23, 2009, 1:59 PM
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adatesman wrote:
anyone lame enough to be online on a gorgeous Saturday holiday weekend morning like me...
-aric.

Don't remind me I'm laid up with a sprained ankle

Hey Aric
I was just checking the strength ratings on Alien cams and saw that they use 5/32" 7x19 cable on all their cams black[33] to gold[1.25]. At Least that's what the website states.
What really concerned me was that yellow to red was rated at 2700lbs and the gold to 3300lbs.
How can this be when a 5/32" 7x19 cable is rate to 2,400lbs in stainless.
Even the Galvanized is only 2800lbs
http://www.wwewirerope.com/aircraftcable/

Just nitpicking I guess but interesting none the less


adatesman


May 23, 2009, 2:16 PM
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Partner mr8615


May 23, 2009, 2:56 PM
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Have you already given us your paypal addy for this? Where are funds being sent?


adatesman


May 23, 2009, 3:23 PM
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