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As I stood by my KK talking with Dennis and I looked for those spot welds, there were none. Apparently it came down to the year of manufacture, that's all, other than that removal with a Dremel cutting wheel would make easy work of any tack weld as you stated. Looking at your break, I'd call that an oddity. For moi, it's pretty straight forward to install, remove the two cap nuts and replace. Weird how it happened though, I opened to take a temp on the meat and the latch stayed in my hand. I said, "this ain't good." So I posted this for those unaware to be mindful of the possibilities, reassure them it's only a speedbump. That's all Folks

What I love is everyone seems to have slightly different failures (in other words, not a design flaw but a random assembly error) and everyone says "Dennis sent me a replacement part" - the worst I've had on my KK was a wooden knob that fell off during a move and after a runaway fire and I also got a replacement. Compare that to the MexiK sites where all the tiles fall off and people need to fix it themselves because the manufacturer is useless and you see the real reason a KK is a great investment.

No warning on mine either, just "plink" and I was holding the handle in my hand. You're correct, Dennis told me that mine had the cosmetic welds after looking at the picture I sent him. He was surprised by this failure; had never seen one do this before. Later years didn't have those welds. Once removed, the cap nuts came right off, and it was an easy repair.

Maybe I'll try my next paella with linguica instead! Reckon the kids may well like some cacoila as well... good suggestions!