2009 Trek Madone Right Chainstay Pierced By Wheel Reflector

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2009 Trek Madone, right chainstay pierced by wheel reflector. A customer took this new bicycle on a test ride and returned with the wheel reflector piercing the right chainstay. From http://www.yellowjersey.org/trekaggr.jpg as of 2009/09:

Most likely, the wheel reflector got knocked sideways or came loose and twisted sideways, then caught on the chainstay as the wheel turned and was driven through the stay. The customer reported no accidents and there were no other signs of damage.

This failure may not constitute "expected use", but it is worth noting that "race" grade equipment is sometimes very fragile and may not be suited for ordinary use. In this case, the stay can probably withstand on the order of 500 kgf caused by chain tension, yet cannot resist a glancing blow from a plastic wheel reflector, which left the corresponding spoke apparently undamaged.

Note also this sort of piercing could also be caused by a stick that is run over and caught in the spokes. That is an occasional occurance and does not typically cause frame damage for ordinary frames.