2nd Gen Non-Engine/Transmission Willmore wheel to wheel nerf bars

[BeefDoc]

4 years ago (nearly to the day) I purchased a set of Willmore wheel to wheel stainless nerf bars for my extended cab longbox 2001. A few days ago crossing a railroad track in town (30mph) the driver's side back mount let go and the bar was dragging along on the ground. I removed the bar completely yesterday and examined where the failure occurred. Apparrently the bars themselves are 304 stainless, but the washer and nut that is welded into the bar where it mounts to the bracket is not. The weld on that washer rusted through and let the bar fall of. I tried to call the company that I purchased the bars from, but the number was disconnected (of course). So I called Willmore - bars are warrantied for life to original purchaser but must go through distributor where purchased for claims (naturally). I tried explaining to him what happened, but he really didn't care. I told him I could have just as well purchased a cheap non stainless set of bars and they would have lasted just as long, why make a stainless bar with non-stainless mounting hardware?? The bar stays in great shape, but it won't stay on the truck for more than 4 years?? What the heck?? He got all pissy and said "we are making nerf bars not washers and nuts (to hold them on)". Finally he said if I sent my bars and all mounting hardware to him he would replace them. From the way he talked to me and treated me, I am not going to trust that he will actually send me anything back. Hence, I will probably have a local machine shop fix the bar that has fallen off.



What a pain in the butt! I spent good money to get a quality product that failed prematurely and get very poor customer support. What a joke.



Just thought I would share my frustrations for the day.



Any suggestions or comments would be appreciated.



FWIW

 

[MarkMiller]

I spent good money to get a quality product... .



FWIW

Good money, crappy product...

 

[Cummins724]

Fixing the nut is alot cheaper than shipping them back. I would fix it also.

 

[jelag]

Stainless fasteners do not have the same strength as a good grade 6 or 8 bolt... stainless steel if it has the right ingredients will not rust... the better grades of stainless the less rust and the less problems with acid... but on the whole, stainless is softer metal. .

In manufacturing its common to see stainless steel 25-30% thicker where mild steel might be used... I was in a box store the other day and a guy was returning all these stainless fasteners because as he tightened them they broke... and he said they were bad... .

The clerk of course had no clue... as I explained the same torque on stainless would cause it to break the guy came unglued... he assumed that stainless because it wouldn't rust was a better metal than steel... . and stronger... .

Your vendor, who chose steel for the fasteners did so for their strength, not their ability to prevent rust, as you can't see them...

But I think the real answer might be the weld... if the proper rod (wire) is not used when you weld mild steel to stainless the weld is weak and will fade quickly in the salt conditions and chemicals used on the road... the best bet here would be a mild steel bar and set up dipped in zink. . but that would cost 3-5 times more for the complete process and outlive 3 trucks...

Customers want both function and looks... my trucks have ugly steps, with expanded metal welded onto the 2 1/2" round tube with 1/4" wall... at least 3-4 times the strength of off the shelf stuff... and the road spray from the front wheels sand blast them every winter... in the spring, we power wash them... and use a can of spray paint to cover the bear metal... and we're good to go... but they do look like sh** most of the time... but are very functional... and cost the same... .

I know its not the answer your looking for, just my thoughts on the matter... I've got 4 trucks and looked at what you bought... and thought for the same money. . I can build stronger... won't look as bright and shiny... . but again mine are work trucks...