Chipped holes in Hobie Mirage Drive

Have chipped the holes where the arms in my Hobie mirage drive 180 clip into the hub.  Not once, but twice.  My son chipped the drive the second time, after only a couple of hours of use with the new hub.

There are probably two "user" related issues here.  First, both my son and I tend to pedal hard when going from point A to point B. A little bit of glide after each stroke would probably be much easier on the drive, and likely much more efficient.  The bigger issue is that my son pedaled with the drive incorrectly seated in the mount points, leaning just a tad bit to the right.  He only did this for about 30 minutes before discovering the error, and getting it properly clipped in.  More than the first issue, I bet this contributed to the quick failure.

The problem with the chip is that the arm wont stay seated in the hole -- it pops out after a few pedals.

I can jury-rig a solution my wrapping the arm with heavy duty picture wire, tying into to adjacent holes in the hub.  But I don't think there is any proper home repair that I can do -- no epoxy it going to stand up to the stress in that spot.

Curious if others have experienced this specific failure?  Found any solutions?

Perhaps bore the plastic out and put in a metal sleeve?

I would not be afraid to try one of the epoxies specifically made to bond to plastic. There should be something at the local hardware store for plastic. I would put some tape over the backside of the two adjacent holes, fill it up, and then refill and sand it flat once cured. Worst case it pops off and you are back where you started.

It looks like those oval crank arms might put additional stress on that area that cracked. I’ve never seen anything like that happen with the square crank arms.

Can you just set it at a shorter or longer position to get it into a good hole? Then put a lumbar pad on the seat to schooch you forward?  Sorry I’m new.

Bring it over to me and I’m sure I can either weld it or use hardened epoxy to form it back.

Perhaps bore the plastic out and put in a metal sleeve?

I think this sounds like a good idea.

And that is some good damage. I’m hard on my gear, but I haven’t had that sort of failure yet on my 180 drive.