Thank you Bob4x4. Excellent post. Exactly my point, good discussion forum material makes for good reading. I would like to respond to some of it to further richen the mixture, and maybe explain some of your observations.
First off, Greg Boardman, as much as I liked him, was never the official voice of KORE. He would have argued that with anyone of course, but he was not a KORE employee. He sold KORE products(sold them well), and drove the hell out of KORE suspensions.
If he informed you of a secret KORE axle truss process and shop near the border, that was a DRC marketing ploy, not a KORE one. No "market cornering KORE logic" there. KORE never has sold axle trusses. Jason Hughes is a great guy, does a great job trussing axles, and probably does not have too much of a varying rate on his work. He sells KORE products also, but his axle trusses are a Hughes Racing Components product, not KORE.
If Greg further misinformed you of true wheel travel, did KORE do you wrong? What Greg did was give you available shock travel lengths. He said 10 inches because you were supplied with a 10" travel shock(compared to the T-Rex 8"). Actually it was a 9" travel shock with the internal top out spacer removed so it would yield 10". This would have required limit straps to limit the droop travel to 9. 5". With this being said, your bump stops were designed to absorb the majority of a big hit and stop the axle near . 25 to . 5 inches from bottoming on themselves. Many of us Dodge suspension geeks have been running around with zip ties on our shock shafts for a long time seeing just how much bump travel we were actually getting. I personally have never bottomed the shock on itself. Each of our trucks is slightly different. I have seen Kent Kroeker thrash his truck with no bumpstops in place, and still not bottom on the shocks. Yours was obviously different. You also did not have the VR coils which ramp up stiffer towards the end of the stroke. Fortunately, the shocks bottoming on themselves will not hurt them. A premium shock bottoming on itself, while not desirable, is not going to do any damage unless you have weak shock towers. KORE has recently worked on a bumpstop that works by bottoming the shock upon itself. Currently the only thing that seems possibly suspect in our application, are the lower shock mounts(Dodge).
I have seen the video of your truck through some sort of sand drags out in the desert. I can assure everyone, as you well know, that kind of pounding will bend any untrussed axle housing regardless of shock brand, size, or valving. Maybe you were told your suspension could take anything you could throw at it, but your truck can not. I have been in a caged, trussed, race dodge and have hit something so hard that it broke a forged wheel, taco'd a control arm, blew out a front driveshaft and sent it up to crack the bellhousing. Much like your situation, the suspension survived, but the truck didn't. The driver over did it. Simple as that.
You have now moved on to the point where you have a truck with an axle housing that you unfortunately had to truss yourself. You now have the ability to drive the truck that much harder than you ever did prior to the axle truss. You know can actually benefit from a much heavier damped 3" shock that Carli supplied you with. You are also presumably running hydrobumps, further enhancing your suspensions capabilites. Sounds like you have a very nice set-up. You can not compare what you can now do with what you could then. I will agree with you on that.
I am glad you are enjoying you Carli system. In the future maybe a few more of us KORE owning guys will show up and romp around the dunes with you. Maybe a few of you guys can come south and rage around mex with us. Even better maybe we will be meeting on the race course.
As for business ethics and conspiracy theories? KORE is a suspension company dedicated to producing top quality suspension components. That's about it. Not much more to it.
I am now employed by KORE, and although I am not authorized to speak on behalf of the corporation, I will on occasion visit these forums and help keep the playing field level here. I believe if we keep to the questions at hand we can provide a thorough information resource without digressing to the ridiculous state that the Pirate 4x4 thread did.
Did this help at all Bob?