Hi Max,
Thank you for the Chaos trace, that will help a lot! I have taken a quick initial look at this, and as you say the physics is telling us that it hits the kerb in frame 315. As to why it does this without actually hitting the geometry, there are a couple of reasons, but it could be that the geometry is getting inflated for some reason within the config. This is getting inflated quite a lot though in this case if that is what is causing it.
I’ll take a deeper look into this shortly, and find out if there is a good way of confirming this - and if so how we reduce the expansion size.
Best
Geoff