[Rick Parker]

A redesign may be in order. To date I have not applied the torque to the nuts for final installation. If I encounter anything similar to what is being spoken of here I will redesign the nuts themselves. Here is what I had in mind. For my application I will take 3/4" round stock, drill and tap the correct threads, machine the correct angle for the chamfer and machine a hex for 1/2" or 9/16" six point socket to fit rather than an internal hex wrench. Or as a cheap fix to the existing ones heliarc a piece of hex stock into the nut itself but allow for overall length and fit a socket to the protruding stub of the hex stock.

Another cheap preventative fix would be to clamp a split collar (machine shop tool) around each nut as it is tightened to prevent distortion or cracking. Just be certain to lubricate the threads and chamfer surfaces with aluminum based anti-sieze compound.

Just my $2 worth!

............Rick