The 8 track had two fundamental design flaws, imo.
First, the endless loop design results in tape that's constantly slipping against itself. Eventually the tape wears out. There is no way around this. Wow and flutter is just a bad side effect on the way to wearing out..
Second, the heads move. This means that eventually the mechanism that aligns the heads against the tape will wear, cross talk will become a problem, etc.
bs
I agree with both flaws. I worked for CBS records and Tapes starting in 1976, just out of school. I was a technician in the Duplication Area where the recording for 8-Track and Cassette tapes were recorded.
At the time we had 17 systems which included one playback "Master" unit and 10 recording units. All recordings were done on spools of tape which recorded the programs one after the other with a tone inserted in between. Eight systems were dedicated to 8-Track, nine to cassette.
All recording was done at 40x playback speed, except for our "audiophile" Masterworks tapes which recorded at 16x. At the end of each run, the 10 spools of tape were collected. One spool from a different recorder was checked by QC. Once checked all spools were sent to de-spoolig.
The de-spoolers would unwind onto a hub (8-Track) or directly into a cassette. A sensor would detect the tone between programs and cut the tape. For 8-Track the hubs would then to go another line which would splice the ends together with metallic tape (causes the solenoid to change tracks) then put them into their cases. They were then put in "indexers" which brought the splice to the beginning.
Cassettes were spooled directly into the cassette. The despooler would draw out the leader and place it across the cutting block. A blade would then cut the leader and splice it to the end of the recorded tape. The tape would then wind into the cassette. When the tone was sensed, the despooler would them cut the recording tape and splice it to the remaining end of the leader. It would then softly wind the leader back into the cassette.
All units would then go to labeling and printing, before finally going to packaging and shipping.
Another problem with 8-Track was the splice would wear out and either break or stop changing tracks. I don't ever remember having a "high-end" playback unit for 8_Track. For cassette we used Nakamichi 700, 1000 and I believe a 628Z units.
We had problems all the time with 8-Track alignments on QC units. We eventually bought drives and added our own control and preamp boards. Cassettes were much more stable. Advent and Wollensack units were used for routine playback on the lines.
I just thought someone might be interested in the manufacturing methods.