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Old December 13th, 2011, 06:14 AM   #1
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Default Almost Alloy Kit Review

I purchased the Almost Alloy Kit from Iron Rock Off Road.
I am putting them in a 98 Jeep Cherokee XJ with a 79 Ford Dana 44 axle with 5.38 gears, lunch box locker and 36" tires, powered by a stock 4.0 motor.
http://www.ironrockoffroad.com/Merch..._Code=IR-S_AAK
The kit came with 8 of these plates

I also purchased new Spicer 5-760 U-Joints.

Full Circle clips from Napa.

I had a set of stock Dana 44 shafts machined to accept the full circle clips.

The U-Joints installed like normal, remember to put the clips over the u-joints before installing them onto the shafts.

I put a little extra grease into the caps because I was going to be welding near them and did not want to burn too much grease out.

First I tacked the plates on and made sure they would fit inside the steering knuckles OK.

They were tight but did seem to just fit.
I welded the Almost Alloy Kit on in steps, just a small bead at a time. With a few minutes between each weld to give them time to cool.
After installing the shafts back in the axle the welds were hitting the lower ball joint nut. I had to grind the weld smooth.

Now I have just enough room to spin the shaft in the axle housing.

The passenger side had a different type of ball joint in it and it required some grinding so it would not make contact with the plates.





I will report back when and how the system fails.

UPDATE
So yesterday (Sept. 1 2012) my front axle shaft broke. I was bound up in some rocks and the drivers side stub shaft broke.
The U joint still feels very good and the "Almost Alloy" plates have seemed to hold up fine.


Last edited by curbdog17; September 2nd, 2012 at 07:17 PM.
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Old December 13th, 2011, 06:39 AM   #2
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How are you going to service a warn u joint? what's the point in full circle clips if you are going to weld a plate on the outside of the yoke?
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Old December 13th, 2011, 06:39 AM   #3
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looks like more trouble then it is worth.
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Old December 13th, 2011, 08:29 AM   #4
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How are you going to service a warn u joint? what's the point in full circle clips if you are going to weld a plate on the outside of the yoke?
I have never serviced a u-joint, they always break first, and the point was to strengthen the ears of the shafts, I have stretched these before and the caps get very loose and sloppy when this happens. The full circle clips will keep the caps in place.

I have never seen a review on this product before and was and still am a little leery about how it will perform. Time will tell. I will post when and how and what fails in the front axle when something happens. But I will not be wheeling again until late winter/early spring 2012.
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Old December 13th, 2011, 08:31 AM   #5
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looks like more trouble then it is worth.
It was not difficult to do, the worst part is waiting for things to cool during the welding process. If I break a lockout instead of a U-joint or the ears off the shaft it will have been worth it to me.
We will see what happens.
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Old December 13th, 2011, 08:32 AM   #6
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Im interested to see how these work out for ya. I was interested in these a few months ago but everyone here steered me away from them. But I wasn't sure why, they strengthen the weak ears of the d44 and cost way less than chromos.

As for failure my money is on either a lockout or a ujoint
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Old December 13th, 2011, 08:33 AM   #7
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looks like more trouble then it is worth.
x2 this looks retarded
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Old December 13th, 2011, 08:37 AM   #8
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Im interested to see how these work out for ya. I was interested in these a few months ago but everyone here steered me away from them. But I wasn't sure why, they strengthen the weak ears of the d44 and cost way less than chromos.

As for failure my money is on either a lockout or a ujoint
I think it was your thread that brought these to my attention. After searching around on the web I found a few threads with people asking about them but no one with any real world usage ever posted anything about them, So I thought i would do a review.
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Old December 13th, 2011, 08:41 AM   #9
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I never broke the ears on my 44 shafts... I broke the inner at the yoke once and at the carrier once. Never the ears, I think the ears break when your turning too hard and on the throttle, mine broke with the wheels straight and the hammer down
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Old March 5th, 2012, 03:57 PM   #10
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The passenger side had a different type of ball joint in it and it required some grinding so it would not make contact with the plates.


I should be taking the jeep out within the next few weeks. I will report back after that.
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Old March 6th, 2012, 11:59 AM   #11
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I'm interested to see how this works....
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Old March 6th, 2012, 12:14 PM   #12
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I'm interested to see how this works....
X2....I just swapped a 60 in mine but curious as to how well these work. I have broken countless Dana 44 shafts and U-joints.
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Old March 9th, 2012, 10:46 AM   #13
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So what exactly does do besides insure you can never replace your u-joints again?
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Old March 9th, 2012, 12:19 PM   #14
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So what exactly does do besides insure you can never replace your u-joints again?
I have seen tons off d44 failed due to loss of a cap or snap ring...
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Old March 9th, 2012, 02:29 PM   #15
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I have seen tons off d44 failed due to loss of a cap or snap ring...
I totally get that and obviously this fixes that problem. But what do you do when you need to replace the joint? Or do you just say fukc it and get a new shaft set. Or do you just get nutty with your grinder?
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Old March 9th, 2012, 02:37 PM   #16
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I totally get that and obviously this fixes that problem. But what do you do when you need to replace the joint? Or do you just say fukc it and get a new shaft set. Or do you just get nutty with your grinder?
Nutty with the grinder. I don't think it will be too bad to cut them off. And in the past I have always broke u joints before I had to replace them.
Time will tell on this one.
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Old March 9th, 2012, 02:50 PM   #17
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I installed a set of these on my dana 30 hp in my xj last summer. I have 33mtrs and a lunch box locker. I have not broke a shaft since. I just installed 4:88s so I will see how they hold up now. I did not burn mine in as heavy so when the u joints do freeze up I can grind them off.
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Old March 9th, 2012, 04:23 PM   #18
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i can see the point, sort of. why not just weld the caps to the ears in a few different areas?
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Old March 9th, 2012, 04:36 PM   #19
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Through expierence I havefound that with stock shafts and full circle clips will stretch the ears/wobble the holes. When I tried this on both my d35 and d44 shafts, after X amount of time the caps no longer fit snug in the holes. By allowing the caps to turn in the softer metal of the stock shafts damages them. I have tack welded my caps since and have had no issues.
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Old March 9th, 2012, 07:59 PM   #20
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Quote:
Originally Posted by CheapThrillB2 View Post
Through expierence I havefound that with stock shafts and full circle clips will stretch the ears/wobble the holes. When I tried this on both my d35 and d44 shafts, after X amount of time the caps no longer fit snug in the holes. By allowing the caps to turn in the softer metal of the stock shafts damages them. I have tack welded my caps since and have had no issues.
I had stretched the ears in my last set of shafts to the point that the caps would fall out when turned upside down.
I am hoping that this keeps it from happening again. I have an odd ball dana 44 and have trouble finding shafts. I need these to hold up a bit longer.
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