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My guess is a super high % of units will eventually fail, with or without a lift. I have a Nov ‘23 unit with 34k miles. Just “Midwest off-roading” - no rock crawling, no lift, no larger tire size.
You would think that Ineos would be all over that sort of thing. They make all sorts of plastics and rubber from their chemicals.
I think you just stop the pinching. But a rubber impregnated Kevlar composite would be fun.
Glad there was no damage.
How well does kevlar stretch?
Well to add insult to injury - half way there, about at Lake Geneva, going 65 on cruise control, there was a rattle from the exhaust, the check engine light comes on, and I got a “powertrain error” message and it went into limp mode. Almost zero throttle response and had to crawl off the highway. Turned it off, put it to sleep, and then restarted it. They said they are having to completely reload all the software. I stopped off at my local independent BMW mechanic (it will be several days before my dealer can get a new drive shaft so I have a loaner) - they said this is not a BMW engine issue they encounter with the B58. So - new turn signal stalk (button not clearing the Jan 1 message because it’s broken), new software, new drive shaft, and fix the windshield wash which is no longer working - a magical confluence of nonsense at 36k
No argument, but are we not at the point with the OEM shaft that the only way to avoid pinching is a redesigned axle or a dropped transfer case? Neither of those seem likely (for current owners), which led to my question about material changes.
It's all in the weave. The Kevlar would be oriented in the mold to allow it to be compliant in the direction needed. Then infused with the EPDM rubber. It would easily move but wouldn't allow tearing.
The OEM shaft has to go. The only way to save the OEM shaft is adjusting the shaft angles or someone developing a new CV that has more range in the boot design, so you are correct.
Sounds like it's not rocket science.
