axel weld

[mooseye]

I have a job coming in the morning that I am not sure about as I have not done it before. I have to weld the axel tubes into the rear housing for a guy.
What rod should I use for this or O/A or TIG, MIG?
Of course MIG would be my first choice if 70s wire is ok

[Sully2]

I have a job coming in the morning that I am not sure about as I have not done it before. I have to weld the axel tubes into the rear housing for a guy.
What rod should I use for this or O/A or TIG, MIG?
Of course MIG would be my first choice if 70s wire is ok

I saw a lot of that back in the late 60's and early 70's. They just used a 60?? series rod ( about 1/8 inch I THINK??) with an AC stick machine. Big engines and a heavy foot have a tendancy to wreck rear ends...

[Aeroweld]

In the past, I have welded 4 or 5 Dana 60 housings for drag racing buddies. Process of choice was SMAW and rod was 7018.

[Pangea]

It's going to be a rosette weld or plug weld, right? My first choice would be good old 7018 and make sure that you get it on the cast housing real good. Second choice would be ER70s and again, get it tied in good to the punkin.

[mooseye]

Ok, it was an 8.8 ford with the plug welded holes. The guy wanted a bead around the outside. Wound up with stick 7018 due to the rust in the crack between the housing and the tubes. He was happy and I was tickled. We used the barter system and he is going to replace the condenser on my wifes ride in exchange. All I have to do is buy the part. Includes vacuum and recharge.
I made out like a big dog, woo hoo.
Thanks for the input.

[Sully2]

Ok, it was an 8.8 ford with the plug welded holes. The guy wanted a bead around the outside. Wound up with stick 7018 due to the rust in the crack between the housing and the tubes. He was happy and I was tickled. We used the barter system and he is going to replace the condenser on my wifes ride in exchange. All I have to do is buy the part. Includes vacuum and recharge.
I made out like a big dog, woo hoo.
Thanks for the input.

Thats where the guys I used to watch welded them. They would hit a few spots down inside that "hole" ( it never looked to me like the car makers even welded a 100% fillet down inside that hole either...just a few short ones??) and then do a 100% weld around the tube / centerbody junction.

[Pangea]

Bad idea to weld around the tube like that. The reason that it is plug welded in the first place is so that the tube stays in the housing. The housing then supports the tube full length and the tube can use its inherent strength to its potential. When you welded around the tube past the end of the housing, you transfered all of the load to that exact area on the tube.

You didn't do your friend any favors with that repair.

[Spook2]

Bad idea to weld around the tube like that. The reason that it is plug welded in the first place is so that the tube stays in the housing. The housing then supports the tube full length and the tube can use its inherent strength to its potential. When you welded around the tube past the end of the housing, you transfered all of the load to that exact area on the tube.

You didn't do your friend any favors with that repair.

I'm not exactly sure I understand your explanation. In any case the plug welds are more to stop the housing from spinning on the tubes rather than to stop them from coming out. The problem is that with big HP, low gears, and oversize tires, the plug welds are many times insufficient to keep the housing from spinning. Welding the tubes in the fashion mentioned is a very common practice in the off road community and when done properly rarely cause any problems. My tubes have been welded 360 deg. where they meet the housing for about 6 years now with no ill effects.

[Pangea]

YMMV The engineers had a different opinion.

[willness33]

Sorry to butt in here, but the Ford engineers weren't planning on an 8.8 out of an explorer (just guessing) turning 5.38 gears and big tires. The tubes are KNOWN to spin under high torque loads. The rosette welds just aren't good enough in those circumstances. I'm guessing this was going in a Jeep? Been there, done that. Several times, in fact. FWIW, any 8.8 I set up gets a 360 degree weld around the tubes as well. I've had no failures after several years of abuse. Now the front axle is a different story.

[Sully2]

Bad idea to weld around the tube like that. The reason that it is plug welded in the first place is so that the tube stays in the housing. The housing then supports the tube full length and the tube can use its inherent strength to its potential. When you welded around the tube past the end of the housing, you transfered all of the load to that exact area on the tube.

You didn't do your friend any favors with that repair.

I..personally AM NOT the one that did the welding. I didnt have the foggiest idea back then how to. I WATCHED others do it is what I stated!

[Sully2]

Sorry to but in here, but the Ford engineers weren't planning on an 8.8 out of an explorer (just guessing) turning 5.38 gears and big tires. The tubes are KNOWN to spin under high torque loads. The rosette welds just aren't good enough in those circumstances. I'm guessing this was going in a Jeep? Been there, done that. Several times, in fact. FWIW, any 8.8 I set up gets a 360 degree weld around the tubes as well. I've had no failures after several years of abuse. Now the front axle is a different story.

Exactly correct! Since the proper place to weld the tube to the center housing cant be gotten to ( the tube as we all know fits into a counterbore) the rosette welds were done for quick manufacturing and nothing more. A 100% penetration fillet weld at the end of the housing tube is the best one can hope for!

[Sully2]

Sorry to but in here, but the Ford engineers weren't planning on an 8.8 out of an explorer (just guessing) turning 5.38 gears and big tires. The tubes are KNOWN to spin under high torque loads. The rosette welds just aren't good enough in those circumstances. I'm guessing this was going in a Jeep? Been there, done that. Several times, in fact. FWIW, any 8.8 I set up gets a 360 degree weld around the tubes as well. I've had no failures after several years of abuse. Now the front axle is a different story.

A 454 -450 HP Chevy in a Nova with wrinkle wall slicks has been known to break the stock welds the very first weekend

[FusionKing]

I've busted a 12 bolt chevy that way and when the pinion yoke bound with the driveshaft it literally lifted both rear wheels off the ground and slung the drive shaft out the side at least a hundred feet!!
Mr Pangea needs to get more informed about high performance mods before he gives out advice...because for safety this is a must do and may even be required. Not to mention any true drag racer KNOWS that this is everyday stuff.

[mooseye]

While we are on the subject, does anyone know a good place to find and 8.8 for a full size 86 bronco at a reasonable price? I have one that blew and is not rebuildable. It is 3.55 and stock will be fine. free,ls,or posi. if cheap enough.