Is this poor manufacturing

[Brian Duff]

a toggle made and installed like that will probably crack. We have had it happen on rigs when we still used that quality of hardware...

[Matthew Sebring]

You should have no problem returning those to the manufacturer. Considering they are "faulty out of the box" you can not be responsible for the shipping costs either. It's very unfortunate that you ended up in this situation but it may just be bad luck. As long as your source handles it reasonably and accepts a return as he should then this should all be somewhat painless - just a delay to your schedule. As a side note, I believe I ran in to you on the cruisers forum. Nice to see you here asking for advice as well. Some very capable people on this forum.

[ribbony]

I have put two stays on the lowers and the gap definitly closed up somewhat as there is reasonable tension on them. But, when it stops raining I can get down and look properly to see just what gaps are there and take a photo to update the situation.

Yes, there are some great forums, each with it's own interest group. Obviously it is great to have a forum that specialises in this rigging topic as it is a very important issue with vessel and crew security at the core of a good rig, performance also but that is not so much a concern for us. The Cruisers forum being very broard base and diverse, then if we have a welding question (steel boat), the MBS is the best place to ask.

[Brion Toss]

Hello,
Sound suggestions above. I'll just add that, regardless of how strong these turnbuckles rate -- or even how strong they actually are -- there is not excuse for this kind of poor quality control. Send 'em back.
As far as the difference in load ratings, I'm curious: did you compare break strengths, or just rated load? Different manufacturers will use different numbers, and the less scrupulous will inflate their rated loads, right up to the yield strength of the material, instead of using a sane factor of safety.
As for mentioning the brand, please feel free! We have no advertisers to offend here, and in any event we all have a duty to wake up manufacturers, and to protect one another from the sleeping ones.
Fair leads,
Brion Toss

[ribbony]

The gap has closed up considerably under tension, but there is still a gap there and the load will still be sitting on 2 points rather than spread around the curve of the toggle/pin .

The brand - "Searig"

The strength of the screws was the "BL (kg)" that is listed in both the Searig and Ronstan catalogues.

Here is a photo of the toggle under tension when installed as a lower shroud.
http://adams35.multiply.com/photos/album/2#3

I did return one swage toggle for a 1/4" wire that had the clevis pin skewed off at an angle as Joe mentioned in his comment on the turnbuckles. Something going on with these toggle plates, wonder if there is subcontracting happening. They used to have Searig stamped on them but these do not.