So this thread got me interested in seeing what mine are looking like, so I just took a look under my rig and it turns out that I have multiple stress fractures, and only one appears to be next to a bolt hole. Just from looking at it, these seem like they are caused by torsional forces, and not impacts; in fact, I have no impacts and/or drag marks on any of my AEV skids that I can find (though I do have a nice one on the factory aluminum one up front and no cracks there, go figure). These skids have been on the truck for about a year or so (I think), and while the truck does see pretty regular offroad use, it has certainly not been abused because it's also my daily driver. Maybe they are brittle; I'll need to email AEV and see what the deal is with these skids either way.Wonder if the material is just too hard for the application. Typically if you increase hardness, you also increase brittleness. You could probably prevent the cracking like Zed suggested w/ enlarged holes or some sort of bushing but these things were designed to take impacts. The cracking from frame/component shifts like this makes me wonder if the material used isn't well suited for the application and if materials with just a bit more flexibility is a good thing in this case. Even if they fix the issue around the bolt holes, I'd be interested in seeing real world results from those who take impacts on their skids. Wonder if they'll experience cracking instead of denting.
Here are some quick pics that I took; pardon the dirt and mud, as I was just wheeling yesterday, but you should still be able to see the cracks with no problem (assuming that my imgur links work, lol).
By way of comparison, the skids that take the most wear and tear (by far!) are the shock skids from 589fab, and they've held up like a boss for well over two years now. 👍