Ok I installed the modified driven spring and took the Pilot for a ride, with the stock silencer
installed for the trip to Silver Lake the Pilot was a real dog so I had installed the 3-3/4" 
spring to bring back some of the bottom end I lost with the stock muffler, I swapped out the 
stock silencer for the super silencer I normally run, it only took a short ride for me to notice
with the super silencer installed and the power back that I need to swap out to the 3-5/8"
spring I normally run. Once I removed the outer cover it was not hard to see the outer cover
cracked! Not 100% what is going on here but I do know that the outer washer did not spin 
and wear a hole through the cover because the line I have been drawing through the cover,
heavy washer and bolt since the first cover failure have always lined up.


When I took this new clutch out of the box I could see the casting was a poor casting, comparing 
it to a old 250 and 350 power bloc confirmed my thoughts about the casting you can visually see
the difference in the castings in quality and thickness, if I had this to do all over again I would have
sent the clutch back for a refund.

Look at the red arrows they point to the shoulder on the bolt and the depression on the washer
.

Another picture of the washer and wear washer, don't leave much contact area does it?

It is real easy to see the uneven wear patterns on the cover I have to theories as to what is 
happening here, look up at the picture of the bolt and washer again the bolt has a small shoulder
under the head of the bolt, when the bolt is tighten all the torque is concentrated in a small area
that small area then compresses the washer, looking at the bottom side of the washer you can 
see the scant contact area the washer makes with the outer cover, now with the 3 sliding blocks 
not making even contact with the outer cover this will rock the outer cover slightly and coupled 
with the small contact area of the washer the cover flexes until it cracks, in this case after about
30 hours of use.


The fix! If I were asked what the fix would be my suggestion would be to find a bolt that allows more
contact area with the heavy washer, find a thicker heavy washer that was made out of harden 
material, make the outer cover to a closer tolerance so the pressure transmitted between the 
pucks and the cover more even, make the cover out of a better quality material.

So now I have a second "new design" clutch that will not shift out all the way with a second 
failed cover, I have tried 2 different driven clutches that work find on the other Pilot and shift
out all the way, I even took both driven clutches apart and inspected them to make sure it was 
not a driven clutch problem and have only used belts from Honda per Harold's request because 
he blamed the belt "from the other guy" for my shifting problems.

More pictures here