The welds on my pedal were undercut, it appears to be what caused the crack in my pedal. I wish I would have taken pictures.Regardless if they crack through the weld and/or metal at the pivot (it happens in both places), the fact is there is too much stress on that area of the pedal for the design and/or manufacturing technique - there isn't enough weld (it's not all the way around the pivot tube). The stress goes through the weld and the immediate area around the weld. Sure the metal is probably crap too which doesn't help with a small weld area, and welding it may make it even worse and more prone to failure depending on the type of steel.
What's the root cause that's putting too much stress in that area? I'm sure not everyone is slamming their brakes on constantly and locking up the brakes, and not everyone has an aftermarket clutch that takes 3x the clutch pedal effort to operate. I'm betting the super stiff OEM clutch spring doesn't help this situation. Has anyone who took out the OEM clutch pedal spring with super low miles have a failure? - I see OrangeCrush5.0 mentioned in post #73 that he took his out when new, but took 45K for his to fail, and just how crappy were the welds on his pedals compared to others?
And I'm betting some pedals are welded better than others knowing Ford's "QA consistency".