Problem
The Flail-Blade flexes upwards from impacts with heavy objects and cuts into Top Hub. Left to continue, would result the the tip of the Flail-Blade breaking off and the possible eventual failure of the Top Hub.
Cause
This is the result of using 1.2mm thick steel, which was supposed to help keep weight down and the thinner blade to slice easier through soft weed and grasses. But when this thin blade hits something hard, the blade would deflect up and hooked over and cut into the Top Hub. If you look closely, you can see the hub plate is smaller than the washers and the back edge of the blade matched the front edge, this is the result of trying to reduce costs by minimising wastage when the parts are lasered from a flat sheet.
This resulted in the blade hooking over the hub where the idea is that the blade should slide under the hub. Even adding an extra two washers on top of the blade, which was suppose to prevent this, did not work when the blade is subjected to a really hard impact.
Solution
Was to increase material thickness to 2mm thick, which gave much more stiffness to the blade to prevent is flexing as much as possible, unfortunately this results in extra weight.
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