Divecoz,
The only logical explanation I can come up with is that the board does sustain some stress impact on the leading and trailing edges when sailing through heavy chop, especially with trailing seas which tend to lift the stern, causing sudden changes in speed. This would likely un-wedge the board from its position and then cause a sudden jolt, causing impact at the points which, as Frank suggests, may be the points least strong (under-engineered by Roger.) Motoring with the board down, which I typically only do when going in and out of harbor at 5 mph or motor-sailing at low speeds when there is no wind and I dont want to drop the main, also causes stresses on the trailing and leading edges, since there are no side loads from sailing/heeling. These areas with the wedged chunks in my previous boards were in places where it sits in the trunk when fully down, top 16".
As for the one that snapped, it probably was as the dealer suggested, unless the same type of damage was so severe that it just broke under stress loads. If the boat sat on the board at low tide, it would theoretically slide up into the trunk, unless there was a bit of an angle, which would then cause it to snap.
Now for the latest. I just installed my 3rd board, since my custom one isnt ready yet. (Going through size issues to get the tolerances to a minimum via having the IDA Sailor Marine send me small plugs the shape of the board-to-be to se how it fits in the trunk.) I used the board for the first time last weekend. There was very little wind and smooth seas. I derigged afterwards and pulled the board up, since my 3rd test plug should be arriving soon and I will need the DB trunk empty. This board, with one use has a 2 long and deep wedge into the fiberglass of the trailing edge.

Im baffled and really concerned. Im now thinking maybe there is something wrong with my boat. I looked through the trunk and dont see or feel any rough areas, so this is truly a mystery. I called the dealer about this and may have them inspect it again, perhaps bringing this to the Mac factorys attention. According to the dealer, I was the only one they had with this problem, except for one or two people who clearly motored with DB down at higher speeds.
