Front Emulsion Coil Over Snapping

[DeadEye200321]

I have this 4" Super Lift installed on my ranger with this Coilover Conversion and I just snapped my second shock a year and a half after it happened again. I'm not doing anything crazy with my truck besides mainly commuting to work and back and the occasionally dirt road. Pulling into my neighborhood after work I hear a god-awful noise and slam the breaks and open my door and see my coilover spring rolling down the road. Looked at my shock and it snapped at the exact same spot. It appears to be due to a fatigue failure noted by the beach lines shown in the photos below

I do have the bump stops that go on the shaft, but I pulled it off for now. I have no idea why this is happening so if anyone has insight to this, it would be much appreciated as I was lucky this only happened when I was pulling into my neighborhood and not on the freeway. Maybe is the coil getting caught on the upper control arm and binding it up and that is causing a moment on the shaft causing it to break? I need to get new limit straps because the ones I have are too big and don't actually limit travel, so maybe the shock having too much travel did cause it to bind up on the upper control arm. Just speculation as to why this would be. Thank you for the help in advance.

 

[pjtoledo]

if I were to guess it wouldn't be linear pulling/pushing but rather rocking side to side, or uneven pressure on one side.
like you said, it's binding someplace during travel.

know any machinists? get the hardness tested on both sides of the break.

 

[2011Supercab]

My guess's

You have the bolt to tight and it can't pivot

Or, you have it mounted to the control arm sideways 90 degrees

 

[DeadEye200321]

My guess's
View attachment 127639

You have the bolt to tight and it can't pivot

Or, you have it mounted to the control arm sideways 90 degrees

Sorry for being MIA. It has spherical bearings in the eyelets and conical shim type spacers for the eyelets so I don’t think the problem is that it can’t move. I did notice the top of the shock mount appears to be hitting the shock cap, could this be where it’s binding? If so, how can I fix that alignment issue?