Wire advice for Ford 8.8 rear end..

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Plan on welding up the axle tubes to the center section of a Ford 8.8 rearend.  Tubes are steel and the center is cast iron.  This will be an Exploder rear end, retrofitted into a Jeep Wrangler.What do you suggest for the wire, using a Hobart 187 welder?Thanks
Reply:mmmm.... popcornI can remember in the 7th grade my mom said "people will offer you drugs" by the 10th grade I was like, "where the hell are these people?"
Reply:Not big enough.  You will need at least 200 amps & .035 wire, preferably .045 wire.  Run it hot, pre/post heat, cool slow in a blanket.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Arc weld with a Nickel rod would probably be better
Reply:Center section is not cast iron, so don't use nickle rod. You need to spend some time reading up on the process for doing this and learning what it is that you have. Also, you may want to find out what axles are going to cost you first, as that may change your plans (big$$$$ for custom axles). You should be asking about how to set this up and jig it to weld it straight, as that is far more difficult than the welding. Also a HH 187 is not enough welder for this project.
Reply:Don't bother welding around the tubes, it won't help. Just make sure the plug welds are in good shape. If the plug welds need work, find someone with a tig to redo them for ya.Ian TannerKawasaki KX450 and many other fine tools
Reply:heres a shot of a mustang rearend i did several years ago....    i used a lincoln 180c mig welder running wide open with .030 er70s6 wire.. you can also see the fuel tank straps are hanging and no fuel tank present, i did alot of welding on the bodyseams, also plated the suspension mounts inside and out, put in a ring and pinion, svo rearend support and moser axles.., it was a pain in the rear literally.. the braces on the bottom side of the rearend actually pass through the lower control arm mount and the lower shock mount.. oh yea almost forgot, i did preheat the center section, my 180c was on the small side and the center section acts like a huge heat sink,also tack weld all the way around the tube first then stitch weld it, i used like 4 beads 1 1/2"long..   its stuff like this is why i want a larger 250amp chassis machine, it pushes the limits of a 180amp machine.. Attached ImagesLast edited by brucer; 07-19-2011 at 03:34 PM.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Originally Posted by Killer95StangPlan on welding up the axle tubes to the center section of a Ford 8.8 rearend.  Tubes are steel and the center is cast iron.  This will be an Exploder rear end, retrofitted into a Jeep Wrangler.What do you suggest for the wire, using a Hobart 187 welder?Thanks