Earlier this year, I was able to pick up a hardly used (less than 10 hours) John Deere D100 Lawn Tractor. The previous owner hadn't used it as a "mulching mower," which I prefer, so I went to my local Lowe's and picked up a mulch cover for the mower deck. As you can see from the picture below, the rear clip is attached in such a way that it will scratch the side of the mower deck. Metal-to-metal contact like that with the vibration inherent with a mower deck will soon lead to rusting. As you can also see, my solution was to slip a small wooden shim in between the deck and the clip.
After trying the local JD dealers, one solution suggested was to snip off the end of the clip so it wouldn't reach the side of the deck. Well, after 20 minutes of sawing away with a hacksaw, I hardly put a dent in it. It might be a lousy design, but it is extremely hard. The other solution was what I had done with the shim. However, the most often repeated response was "Well, no one's ever complained about it."
Here's how the shim fixed the metal-to-metal problem.
That's a sad commentary on what we Americans have come to expect from our "Made in the USA" manufacturers. After playing with it some more, I was able to force the clip through the slot from the inside out so that the pointy end was not coming in contact with the side of the deck. However, there is still metal-to-metal contact, which, with the inherent vibration, will abrade the paint on the deck and therefore will still require the shim.
I just find it hard to believe that a competent engineer couldn't figure out a better way to design that clip so it would accomplish the task of keeping the mulch cover in place without damaging the mower deck.
I sent a letter to the CEO of John Deere, including the attached picture, describing the issue and asking for their input. As of today, I'm still waiting for a reply. I guess the "monkeys" can't write... or design.
This entry was submitted by Ken Brindle and edited by Rob Spiegel.
Tell us your experiences with Monkey-designed products. Send stories to Rob Spiegel for Made by Monkeys.
We are the problem. Corporate America makes cheaper products because the consumer demands them, not for excessive profits as you call it. American Corporations must compete against subsidized factories and shipping and companies with newer equipment paid for by US aid programs, most notably the Marshall Plan. Then you must add in cheaper labor and Ameriphobes, who willingly accept deficiencies in some foreign products.
Just because nobody complained (and that isn't true, because you are not nobody) does not mean it is great design. Besides that, studies show that 2/3rd of all customers who have reason to complain don't do so. In this case many may not make the connection between the metal on metal vibration and rusting.
Another option would be to wrap the hook in sturdy plastic. That could wear off after a while, but that depends on how heavy the vibration is.
It appears like the simplest fix would be a plastic tip covering the bare metal. If you look at most bungie cords, the end of the hook is covered with a small plastic tip. Of course that can come off when you remove the hook from the hole and put you right back where you started. Another solution may be to reform the tab in which the hole is perfed.
I have a Craftsman mower and the tab is far enough away from the deck that rubbibg is not an issue. My problem has been pulling the rubber strap off. At the end opposite the hook, the strap is anchored by a shoulder rivet. As you stretch the strap, the hole for the mounting screw also stretches. I have pulled several off the rivet and have never been able to get one back on. So I stretch a bungee cord around the rivet and put both hooks through the hole. I guess it doesn't look very pretty, but it works. I am sure that makes me one of those that accept substandard work, but to be honest I am really more concerned that the mower starts, climbs the hills in my yard, mows and the bagger works when I want it to.
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