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I know this is many many years ago but when I use to put the nose cone on the front corner of the 1978 impala if our gun was set at too high of a tourque it would show a hairline crack which could exagurate when the car hit a big bump. Yes even at 25 mph.
This could be all it is and just a slight loosening of the nuts holding the front facia on could cure the problem. Just a thought. Agree this should be caught during the build.
I have no doubt that some of these slipped out the door back in 1978. PS some may have been to tight and did not show the crack at the plant also.
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