Short of doing something completely odd in terms of "procedure", the discs should not fail unless there was a manufacturing glitch.
I would return those discs and have them replaced under warranty.
There have
been instances of premature failure (and we've read about them), so I suspect that something went awry during the manufacturing of a batch of discs. I have never seen the manufacturing process, but I can assure you no expense was spared to ensure a consistent and durable product leave the plant.
Could be something as simple as a "glue glitch", where not enough was sprayed, or who knows what. Whatever the cause, the percentage of failure is incredibly low, but if an issue arose during an early batch run, we would see it on the forums because a lot of us purchased introductory kits.
I personally spent all sorts of time trying to get those little things to fail, and never saw a catastrophic failure until about six weeks ago. I was using a 5.5" disc, felt a shimmy, and the disc split in two (the way you might twist an OREO cookie into two)! No harm done, but I reported it immediately.
There's simply too much time and money invested in this product to accept failures, and from what I know, the issue is not being taken lightly. Pretty sure the failure rate is negligible (perhaps less than 1 out of every 1000), and you'll know within minutes. Should be no issue getting a free replacement. Confidence is very high that this is not the norm.
It's a big deal when you're excited to use the system and the disc comes apart, so I understand your frustration. Meguiar's will appreciate your frustration, and will certainly do whatever they can to make things right with you.
And if by chance you cannot get a free replacement, I will take care of it myself, and send you some replacement discs from my personal stash.
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