1/ 100% it will fail.
I simply do not agree. There is minimum stress on that bearing or on the welds themselves. I do agree that trying to weld into a hardened steel race is not a good practice in any application. I assumed, and probably that is a bad thing to do, that there would be more substantial welding afterwards and what we see is just an intermediate step.
2/ It's the steering, it offers the worst case senerios over any other component if it fails.
I can't say that steering is any worse than any other primary system failure. the failure of a front (or rear for that matter) control arm, or total loss of brakes, for example. Yes, loss of steering is a very bad scenario. But this application, the total loss of steering is not the failure mode.
3/ The failure will be instantaneous.
Failure of separate welds will be sequential. Detection of the final weld failure may be instantaneous.
The shaft is in a tube so danger from failure probably not so bad, the shaft really can't go anywhere
That was exactly my point. In this application and in this design, IF
it fails, the car remains under some control.
I do agree that welding to a bearing is not a good practice and should not be promoted. I was not promoting the proliferation of this. I thought that my comment about the alternative would show how much easier and safer my method was. And there are other safe methods too. However, I have seen a lot of other designs/practices that scare the bejeesus out of me on this site and I would never try those things on my own car.
I, too, post for the further education of others and not for my own gratification. Even if we have different viewpoints, I think that both opinions are valid. I am not as confident as you that failure [url]will[/url] occur or that people and /or property damage is imminent. But to be ultimtely safe, any future builder should stay clear of this practice. I am also not as concerned about the legislators screwing up our
hobby. There are a lot more shade-tree mechanics doing stupid things to maintain their factory built cars. Heck, I've done things in the past to keep my regular cars on the road that I'm ashamed of today. If anything, there would be new laws to prevent anybody but licensed techs from repairing any car, period. That will be a long way off.