Leatherman QC Fails

[hennypenny]

I'm fairly new to Leathermans, but in my short time collecting Leatherman tools, I have encountered several QC issues, even on the more expensive tools such as the Charge TTi & Charge AL. I do have a few SAKs, such as the SwissChamp, Classic, Compact, Climber, Manager & Explorer. All of them with absolutely no QC issues. But, for some reason, I still prefer Leathermans rather than Victorinox, and continually forgive them for minor defects.
Let's start this thread to compile all the QC failures you have with Leathermans and hopefully, this will embarrass Leatherman into improving their quality.
I'm going to start with my Charge AL, which has the diamond file that rubs on the inside of the black scale handle.

[cowsmilk]

Would you be willing to illustrate your own QC challenges first? I haven't yet had any QC problems with my leatherman tools.

[hennypenny]

There's too much of a gap on the closed jaws on both my Charge TTi. I realise they are not meant to close completely flushed, but the gap just seems to be too wide.

[cowsmilk]

There's too much of a gap on the closed jaws on both my Charge TTi. I realise they are not meant to close completely flushed, but the gap just seems to be too wide.

I see what you mean. I'm not sure if I would personally consider that "by design" or a QC concern. I'm not bagging on you, I just really don't know.

I would suspect that the teeth should line up when closed and should gap evenly across the grip face, but this is my opinion.

[bmot]

There's too much of a gap on the closed jaws on both my Charge TTi. I realise they are not meant to close completely flushed, but the gap just seems to be too wide.

I see what you mean. I'm not sure if I would personally consider that "by design" or a QC concern. I'm not bagging on you, I just really don't know.

I would suspect that the teeth should line up when closed and should gap evenly across the grip face, but this is my opinion.

I do think leaving a small gap ensures that the pliers will always meet at the tip first, which is what you want for fine work... I suspect this is by design... Though both my Ti (without capcrimper) and Skeletool have a much smaller gap.

[Nhoj]

When I put the pocket clip or removable lanyard ring on my wave the tools on that side become extremely difficult to get out and clump. I might send it to Leatherman eventually but it hasn't been too big of a problem.

[Bensasupertool]

Super loose tools in the locked position on the new Rebar. Really disappointed with the tool now. With the massive output of LM products im sure they only take a few samples out of a batch to look over. Then again there is the assembly of the tool. QC shouldn't fall short there and be paramount you would think. I'd hate to say hit or miss with the newer products put compared to the old stuff it seems to be.

[bmot]

I never had a new Leatherman tool disappoint me, my second-hand Wave was pretty rattly, but I don't know if that's because of use or because of bad QC.

[Cupboard]

Both my Fuse and Skeletool pliers are like that, as is my Spirit. The only one with less of a gap are the Rebar pliers in my Wave.

[Zed]

I think a lot of the pliers on old and new lm's have that gap,never a issue for me personally, rusts another problem I've not suffered with but heard many complaints,let's face it we can be hard too please   

[Bensasupertool]

Here's a pretty sweet QC fail to the max. Cross cut dog rolls anyone?

[Top-Gear-24]

I also have the feeling that the "older" Leatherman tools had better fit and finish than the new ones, I've had some problems with a few of the new tools ... 

Here's my Rebar, after looking at it, playing with it and taking some pics (no real use):



More about my Rebar can be found here.

Then I had my Charge TTi with a ruler flaw, see pic below and read here.



And on one of my ST300's the plierhead rubs pretty hard against the tip of the blade when I close the tool (no pics from that one, maybe I'll take some later).

But I must say that I still love Leatherman tools very much, before you guys think I'm a Leatherman hater  .  But I will never buy a Leatherman online or in blister pack anymore, if I buy one, I'll have to hold it in my hands and do the QC myself, so I'm sure it's a good one  .

[Gilliand]

I'm going to start with my Charge AL, which has the diamond file that rubs on the inside of the black scale handle.

Exactly the same issue with my 2012 Charge TTi

[Syph007]

I also have the feeling that the "older" Leatherman tools had better fit and finish than the new ones, I've had some problems with a few of the new tools ... 

Here's my Rebar, after looking at it, playing with it and taking some pics (no real use):

(Image removed from quote.)

More about my Rebar can be found here.

I have to do a +1 on this exact issue.  My new and rarely used rebar is having the exact same issue as pictured here, and even the exact same side.  Mines not all the way off yet, but loose and I can see where the rivet material is beginning to fail.

[BigMatt]

Leatherman functionality with Victorinox quality... Maybe one day.

Charge AL - file scraping scales, serrated blade catching on scales-blunt.
Surge - cracks where handle material was folded (missaligned handle "butts"), unevenly mashined handle and outside tools edges (uncomfortable to hold).
Rebar - when fully open and squeezed like grabbing something, pliers pivot locks up and becomes very tight.

Not sure wheather a QC issue but another Surge after cutting hard wire (coat hanger type) developed a significant play in pliers pivot. It never sheared/got stuck in the cutters. And no damage to the cutters, just "stretched" rivet...

[Philby]

Last new leatherman I bought was a Rebar with loose tools, before this was a supertool 300 with the wire stripper ground out too high mis-shaping the can opener.  Both tools returned, no complaints with the replacements. However two new tools being defective is too much of a coincidence, sort it out! It seems to me that there is a perceived difference in quality post SUPERTOOL 200.

[BigMatt]

I have to admit, "old" ones I had like the Squirt, Charge Ti, Blast or Kick, gave me so much more confidence than Charge AL, Surge or Rebar. Every single one had something wrong with it. And that cardboard feel in your hand.
I'm still after the usability and ergonomics but I really crave thet fit and finish of the Victorinox.

If they cut more corners wit the new Suge I would seriously rethink what I say to people about Leatherman...

[Mercury]

 Not to nitpick but the squirts, Charge Ti, Blast, and kick were all in production at the same time as the AL and Surge.  They are all "newer" tools.  I have had very similar issues with all of them.  The older tools like the original Supertool, PST/PSTII, Pulse, Mini, ST200 and the like, were the sweet gems of the multitool world.  Nothing has come close to their fit and finish except the Swisstools.  The only Leatherman tools I have had that had no QC issues were all pre-2002.  That's not to say that all the tools produced in the 90's were perfect, but in the same breath not all tools produced since 2010 have had poor QC.  Leatherman is still a great company, they just need a nudge back to what they used to be.

And to be honest, out of all the ones mentioned in the above post, I have to say the Rebar has the best feel to it.  I detest the thin blade stock used in it's construction, but it does remind me of the old Leatherman, at least until you open it up.

I'm a huge fan of the Blast, but even I can concede that it feels much cheaper than even the all metal models.

[BigMatt]

For me last few years with LM are problematic. Maybe I simply look closer after the charm weared off.
The point is, 4 out of 9 LM I had in my hands had some issues, and one of them (rebar) had to be send back straight back from the box...

[Carthas]

I like this thread. Not so much of a "I hate Leatherman" rant, but more of a "Hey Leatherman, love your product but here are a few issues that would be great if you fixed"

[BigMatt]

Exactly +1

[kkokkolis]

My serrated blade rubs the handle of my Surge. I tighten it and after a few uses it happens again.
Some bits are impossible to get out of the bit extension without the use of pliers.

[sawman]

I think there should be a $10,000 USD fine for each bad quality LM that goes out the factory 

[AimlessWanderer]

This thread wouldn't be complete without mentioning ...

Juice Can Opener (unfinished)
Juice Wine Assist (ineffective and damages bottles)
Juice Scissors (catching frame and erratic pivot tightness)
Juice Saw (deviating to back of awl on closure)
Juice Awl (unfinished)
Juice flat drivers (ouch, ouch, and ouch again)
Squirt - erratic build, tools (particularly blade) fouling scales on closure
Squirt & Style PS scissors spring
All small tools (IMO) inconsistent peening

[Syph007]

Juice flat drivers (ouch, ouch, and ouch again)

Ya you dont pull them out for no good reason.  You really need a flat driver if you want to endure the pain.

[MeadMaker]

I am a LM fan and I carry a Juice most days, but I have to say that LM could do a better job on the profile of the Juice main blade.  It is very inconsistent from one Juice to the next. 

[Metropolicity]

The juice's down fall is its rivet construction. It's really hit or miss.

Once I replaced the pivots and tensioned it, the blades, drivers and scissors are wonderful.

[Mercury]

For me last few years with LM are problematic. Maybe I simply look closer after the charm weared off.
The point is, 4 out of 9 LM I had in my hands had some issues, and one of them (rebar) had to be send back straight back from the box...

I agree that they have had more issues recently, but I was merely pointing out that all the tools you mentioned are part of the same "era" of tools if you will.  To say a tool is "older", most of us here at least think of the PST and Supertool and the like. 

[Bensasupertool]

I got another blow to the Rebar, and was a little pissed cause I wasn't the user to find the flaw. The awl was a center punch for a few holes we needed to make. No hammer was used, but I want to beat the tool now. The awl deployed and the rebar folded up the plier head gets wedged in between the small and large flat driver. Every time its folded up. Such a pain to hear grinding of metal on metal. 

My coworker asked me what the tool cost cause he thought he broke it. Told him don't worry. its got a nice warranty I cant wait to use. I should get two new BO PST's in return. This just sucks. I had high hopes for the tool, being a ST300 fan.

[hennypenny]

I got another blow to the Rebar, and was a little pissed cause I wasn't the user to find the flaw. The awl was a center punch for a few holes we needed to make. No hammer was used, but I want to beat the tool now. The awl deployed and the rebar folded up the plier head gets wedged in between the small and large flat driver. Every time its folded up. Such a pain to hear grinding of metal on metal. 

My coworker asked me what the tool cost cause he thought he broke it. Told him don't worry. its got a nice warranty I cant wait to use. I should get two new BO PST's in return. This just sucks. I had high hopes for the tool, being a ST300 fan.

Perhaps you could mod your Wave with Rebar pliers!