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@nev
It wasn't the rack that snapped, it was the driveside rear dropout. same place both times. Ted welded it up for me and it's ok again.
It snapped because the dropouts on old kona's are on the weedy side, add to that the fairly small circumference of the tubes of the rear triangle and the fact that it's fairly compact and you get a lot twisting at the back under load.
the yellow Kilauea on the other hand has chunky cast dropouts and rear stays that have the same circumference at the bottom as they do at the top making the flex is negligible.