Knuckle Ball Gusset Kit

[4RnrRick]

I'm helping a buddy swap some toyota axles under his Sami, and he got this kit from you guys. I really like the beef in these plates, and the provision for a shock mount but theres one MAJOR problem!!! And why this problem was not address before they ever went to production just baffles me.... Basically we had to trim down the Top Gussets to make them clear the seal plates! And since we where building a axle from the ground up they were already fully welded on! so getting in there to trim that piece out carefully without damaging the knuckle ball just sucks! All you guys have to do is to change the burn program.....

[notajeep]

Are the steering stop caps really that important?

[BigMike]

Good eyes notajeep, I didn't even see that

Rick,
I spoke briefly to Dave about this, who was pretty busy and has not see this yet, and he told me that on most axles it does not need to be trimmed down. I need to look into it some more for myself, but as far as I know right now, for most applications, this is not required.

I thought that all 1979-1985 8" front mini axles were all the same at the knuckles, so I am not yet sure what he is talking about...

I'll try to follow up on this soon
Mike

[MiniSimp]

Are those the stock seal plates? Or aftermarket thicker ones?
Picture is playing tricks with my eyes.

[4RnrRick]

I spoke briefly to Dave about this, who was pretty busy and has not see this yet, and he told me that on most axles it does not need to be trimmed down.

Well, I will have to repectively disagree.... even the picture CruzrDave posted above shows them trimmed down....
(see attached photo below)

I need to look into it some more for myself, but as far as I know right now, for most applications, this is not required.

After instaling these myself - I will once again have to disagree.... I fyour running seal plates - they will have to be trimmed.

I thought that all 1979-1985 8" front mini axles were all the same at the knuckles,

They are ALL are the same....

I'll try to follow up on this soon
Mike

Thanks for looking into it. And like I said previously - I really like these gussets and I will probably even recommend them to other people - but this one issue I had pissed me off because I just expected it to be RIGHT.

[4RnrRick]

Are those the stock seal plates? Or aftermarket thicker ones?
Picture is playing tricks with my eyes.

They are the STOCK sheetmetal ones.

[abnormaltoy]

I'm helping a buddy swap some toyota axles under his Sami, and he got this kit from you guys. I really like the beef in these plates, and the provision for a shock mount but theres one MAJOR problem!!! And why this problem was not address before they ever went to production just baffles me.... Basically we had to trim down the Top Gussets to make them clear the seal plates! And since we where building a axle from the ground up they were already fully welded on! so getting in there to trim that piece out carefully without damaging the knuckle ball just sucks! All you guys have to do is to change the burn program.....

I just ordered this kit...it'll be interesting to find out how mine fits. I can't see how some would fit and others wouldn't, although I noticed in an earlier reply (#19) the picture shows the top bracket has been ground to a "knife" edge. I should get mine by Tuesday or Wednesday and I'll let you know.

[DTB]

Note: Some grinding may be needed to trim to fit these gussets. Welding, cutting and grinding required.

not sure if you saw the disclaimer 4rnrrick

[ddog87]

    not sure if you saw the disclaimer 4rnrrick

But not a 1/4 of an inch of material from the gusset. I had bought mine before Rick did theres and was able to let him know of this problem before they had the axle full assembled and on the trail ( NOT THAT YOU COULD GET THE UPPER FELT RING ON WITHOUT GRINDING) So it's not just one case of this happening, don't get me wrong love the product just alittle disapointed

[4RnrRick]

    not sure if you saw the disclaimer 4rnrrick

I seen the disclamer... But like I said, the whole reason for buying this"kit" is so you don't have to screw around and make your own gussets and knowing they will fit the first time. Obviously there will be some cutting/grinding/welding since your FABRICATING... I REALLY like the beef in these, and I will probably even order a set for my next axle build. I just cant for the life of me understand how this missed the protoyping stage of product developement. And like I said - I already had them welded on 100% since I was working with a bare housing and then DDog87 informed me of a possible problem. then just like DDog87 had said - I found the problem during assembly.

Please understand that I'm not trying to BASH the product - I really do like it - I'm just simply pointing out a problem area that could be easily fixed in the burn program.

[abnormaltoy]

I just ordered this kit...it'll be interesting to find out how mine fits. I can't see how some would fit and others wouldn't, although I noticed in an earlier reply (#19) the picture shows the top bracket has been ground to a "knife" edge. I should get mine by Tuesday or Wednesday and I'll let you know.

I received mine today and hastened to the garage to check the fit. A quick look tells me I have to trim off probably a 1/4 inch and bevel the edge.

[Rockdiver]

Hey rick were you using the thicker  rings for the felt on this install?

[MiniSimp]

Are those the stock seal plates? Or aftermarket thicker ones?
Picture is playing tricks with my eyes.

They are the STOCK sheetmetal ones.

[Rockdiver]

Thanks Mini I am Blind   Little trimming and my thick plates are on 

[4RnrRick]

I'm helping a buddy swap some toyota axles under his Sami, and he got this kit from you guys. I really like the beef in these plates, and the provision for a shock mount but theres one MAJOR problem!!! And why this problem was not address before they ever went to production just baffles me.... Basically we had to trim down the Top Gussets to make them clear the seal plates! And since we where building a axle from the ground up they were already fully welded on! so getting in there to trim that piece out carefully without damaging the knuckle ball just sucks! All you guys have to do is to change the burn program.....

I helped a Buddy install this kit last weekend (which he just bought last week from my recommendation) and I was shocked that we STILL had the same problem as I did 1 year ago and you guys haven't fixed it. Please just change your burn program to nip the end of the upper gusset off so the end user doesn't have to deal with it. Sure I understand that you guys buy large quantities to keep the costs down - but I would have thought that 1 year later this issue would have been fixed.

PLEASE understand that I LIKE this kit the best on the market because its uses nice long beefy plates and the shock mount is super simple - I'm just trying to get you guys to improve it. and I will keep recommending people to buy it, but its also in my nature to tell you about the flaws in it so you can improve it.

[BigMike]

Rick: Noted

[4RnrRick]

Thanks - Thats all I ask.... Okay not really - 

It would also be cool if you guys could also relieve the gusset for the knuckle weld area slightly also. 

[kneedownnate]

That seems like a good idea too!  Both mods would be easy enough to do before mounting them but, if you don't know they should be done then you're in for a headache trying to jimmy rig it

[Aggietaco]

Went to install mine tonight and figured out that this issue still hasn't been resolved.  20 minutes with the bench grinder and they fit, but still...

[COToy91]

back from the dead lol

[toyyota]

I Installed my third set today, On the later housings that I've been using, 84,85 I've trimmed up to 1/2 inch , and put on that knife edge you guys saw, to clear the felt seal. As far as the steering stop blocks, gussets, I think this can greatly improve the overall strength of the front housing. Be careful welding, not to build excessive heat causing worpage. These housings are getting harder to find, that aren't already bent.

[DTB]

I think the main problem is that you have to pretty much install the knuckle to know where to trim the gusset...then the knuckle has to be removed....gusset trimmed...knuckle checked again for clearance...removed again....then welded on....then knuckle installed again..

Those were the extra steps I went through...not hard but I would have made them myself if I had known what was necessary

[Talon84x4]

When I helped a friend install his I trimmed just as rick has shown and they fit perfect the first time with the right amount of clearance. 

[Ironloki]

stupid question here.. im assuming the top piece is to be square with the leafspring perch?  k thanks.

[Volcom]

stupid question here.. im assuming the top piece is to be square with the leafspring perch?  k thanks.

I'd make sure they are straight up and down to be most effective.  They might not be square with the perches.

[Ironloki]

the axle's not even close to being in the truck yet, so i wouldnt know exactly where TDC is on the housing.. Kinda figured it'd be with the perches level to the ground.. Ill make sure to triple check everything 4 times before I make it solid.

[Pariah]

These are definitely on my list for near future upgrades

[Volcom]

Best pics I've got when I installed the gussets.  I guess they are pretty close to level with the perches.




I installed the small spacer for the shock hole wrong so don't follow this picture 

You can tell how much grinding I had to do to make them clear the backing plate bolts.

[peacesells]

I was given 2 kits, I had to grind a ton off of the uppers to test fit them properly and by the time they are ground down I dont think they add all that much strength. I also had to cut one of the lowers to fit also, but they have much more surface contact with the ball and I think add the majority of the strength in this kit. The steering stop plates are a must have. I reccomend them to anyone who doesnt drive like grandpa, good insurance.

[MixedBag75]

I've got another stupid question:

Do I have to have the axle torn down to weld these on or would the welding completely boil the grease in the knuckles upon welding?