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Sorry to hear the Beetle is sick.
Do you have a close up pic of the break? That will tell how and why it failed. There is a few scenarios that can be pin-pointed. Fracture mechanics was one of my hot subjects at University.
I've not seen a 'bolt-on Kafer-bar' set up yet that impresses me, even the new Bugpack piece looks medioka. The CSP looks alright, if it wasn't for the cantilever tabs, which result in improper triangulation. I don't believe this'll be the first failure of this type when using monoball. Are you concerned about the amount of strain you're seeing? It sounds like a tensile fatigue failure brought on by flexing of the rest of the car, not any of the 3 torque bar links. I would have the diagonals copied in steel.
Matt
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'79 Karmann, Nrburgring or bust...
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