3:02 p.m. on September 27, 2012 (EDT)
OK, I've finally gotten my images ready showing various gear failures. They range from rather petty (hook coming off Dirty Girl gaiter) to having more potential impact (tent zippers failing), to downright serious (pants falling apart, including stitching on the pockets containing my ID, cash, credit card, etc ... and stove not holding pressure ... etc...
I'm not sure why I have so many gear failures. I feel like I take pretty good care of my gear, and some of the failures occurred early in the items' life. I've had similar issues with my Nikon DSLRs (3 of the 3 I've owned have had issues requiring that I send them in for repair). Similarly, one of my Nikon lenses had a focus issue from day 1, I had it repaired, and then partway thru the JMT trip the issue returned. I'm really disturbed at the level of workmanship I'm seeing in products I buy, even after doing exhaustive research in selecting the items. And it's not like I'm buying bargain basement brands either. Grrrr...
This thread kinda got me going (that's one reason I waited a while before posting ;). As someone who tries his best to do his best work every day, "poor quality workmanship" is a real pet peeve of mine. Not only that, but particularly on a long thru-hike, even a failure that might seem relatively minor on the surface has the potential to seriously impact (or even terminate) the trip.
Here are some samples:
Both door zippers on my Mountain Hardwear Skyview 1.5 failed last year. This issue is pending a cleaning of the tent so I can send it in to see how MH will handle it. The tent is >12 years old so I guess they'll probably charge me for the repair. I'm not complaining about this one because it happened after years of use, albeit light use...
Door #1

Mountain Hardwear Skyview 1.5 door #2

Big Agnes Copper Spur UL 1 door zipper failure. This tent had only been used for maybe 20 nights or so when this started happening. This one, too, is pending a cleaning & filing of a repair request; hopefully given the premature failure it'll be covered under warranty even though I've had the tent since 2010.

Salomon S-LAB gaiters. These were brand new for my 2012 JMT thru-hike. They started ripping on day 4 and got progressively worse. If you expand the photo and look closely you can see where I used SuperGlue around the edges of the rips in an attempt to harden the fabric to stop the tearing. That helped for a while but the rips continued. Finally I was able to get a needle/thread & sew up the worst rip ... but even after that new tears started. I discarded these midway on the trip when I discovered they sold Dirty Girl gaiters at one of my re-supply stops.

Dirty Girl gaiter, one of the little hooks that holds the gaiter to the front lace came off. Fortunately it happened when I was stopped so I didn't lose it. By that time I had needle/thread & was able to reattach it.

REI Sahara Convertible Pants: these worked well design-wise, but the assembly quality leaves something to be desired. Here you can see the stitching on the "hook & loop" pocket fasteners just completely disappeared. From that point on I had to routinely (obsessively?) checked to make sure the pocket contents hadn't fallen out (and I didn't think it would be wise to leave my wallet in my pack, in case I got separated from the pack in an emergency).

REI Sahara Convertible pants, more failures: First there's the obvious total failure of the seam protecting hikers behind me from seeing whether or not I was wearing clean underwear. Secondly, and probably more importantly :) is that you can see where the stitching on both rear pockets mostly disappeared. This left the inner pocket material just flopping around unattached. Needless to say, if I hadn't noticed this in time, anything in those pockets would have fallen out. Initially this included my "hiking wallet" (including drivers license, credit card, cash, claim check for one of my re-supply buckets, etc.). I didn't take note of exactly when all this started, but IIRC it was maybe about 10-12 days into the trip, and certainly no more than 15 days.

here you can see the inside view showing the pocket material flapping loose.
I guess I'll take them to REI to get them replaced. Part of me feels that since I used them for the whole JMT trip I should just consider them a trip expense. But, still, it seems to me that a $65 pair of pants should last longer than this, especially since the failures started relatively early in the trip. I'm pretty sure I was using them for their intended purpose.

I've also had a couple of failures with my Deuter ACT Lite 65+10 pack which was brand new for this summer's JMT hike. Fortunately both turned out to be very minor. One failure involved the fastener on one of the "carry loops" on the side of the pack coming off. I was able to work around the failure by tying a knot in the stretchy cord. The second failure also involved a fastener coming off. This one was the one that tightens the top pack compartment shut. Fortunately I wasn't using that one on this trip (I used the one on the "extended" section at the very top of the pack).
Here's the fastener from the top compartment. I thought I'd lost it but it had fallen into a flap on the pack, so I found it later.

This is one of the fasteners on the side of the Deuter ACT Lite 65+10. There's one on each side of the pack. I used them to carry my water shoes. Fortunately this breakage occurred while I was attaching them, so I didn't lose the shoe it was holding.

On day 13 or 14 of my JMT trip, I also started experiencing a failure of my MSR Simmerlite stove. I found the pump wouldn't hold pressure. All I ever needed to do was boil something less than .9L of water. The stove worked great up to this point. But I noticed the flame would start petering out shortly after I started it. I tried pumping up the tank without even attaching the burner, then opened the cap, and there was no pressure (no escaping hiss sound). I tried applying pump cup oil to the pump cup, and I thought that helped, but the problem came back the next day. Ultimately I ended up replacing the check valve at the bottom end of the pump assembly.
The one on the left (with the flat disc at the end) is the one I removed. The one on the right (with the rounded piece at the end) is the one I installed. I don't recall whether I had swapped these during the stove overhaul/maintenance I did using the MSR Expedition Repair Kit just prior to the trip. But in any event, the original one worked find until partway thru this trip. Replacing it with the rounded piece solved the problem for the remainder of the trip.
In hindsight, I also see now that in addition to the rubber tip being of a different shape, the spring on the one I removed seems more compressed than the replacement. Maybe I could have stretched it out...
Anyone with a Simmerlite care to take a look at the pump to see which style check valve you have? :)

and a close-up of the check valves:
