Cast to mild help

admin

I know it's like asking an auto mechanic to diagnose that sound over the internet, but I thought I'd ask and show you guys anyways.I'm attempting to weld the tubes on a ford 8.8 rear axle to the housing so they don't spin under my Jeep. I've got my Lincoln 175 setup on D-3 and I'm using .035 flux core. I'm not terribly concerned how it looks but how well I'm penetrating and if it's going to be strong. Unfortunately, this isn't something I can cut apart and test. I preheated the cast to help with the dissimiliar heating and cooling and this is what I ended up with on my first try. Any thoughts? Attached Images
Reply:looks good so far....if you go all the way around you'll be just fine..(jeeps dont make enough tourque to get in trouble) another method is to stick weld it with 7024.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I've been told the best way is to stick weld it with a high nickel rod, but I have to make do with what's in the garage. Unfortunately, ford didn't weld their tubes in like a dana, they just have molten plugs in the housing to the tubes, so plenty of guys have rotated a tube on a 33"+ tire and the pinion climbs up and destroys the driveshaft, u-joints, etc.Thanks for the help.
Reply:you should be just fine with that...just for laffs after its painted..put a white dot on the housing and one on the tubes where you can see them easy enough next to each other..you'll be able to tell if "rotation" is happening before its too late......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Maybe I shouldn't, might be better that I don't know how horrible my welds are.
Reply:like zap said it looks good so farChuckASME Pressure Vessel welder
Reply:I believe most differential housings are cast steel and your weld looks like that is the case.  I've only welded one of them (tig) and it came out really nice.
Reply:Which flux core are you using, if I can ask.
Reply:Why are you welding it around there?Reason I ask is they are normally plug welded through holes in the cast, I think welding around the tube like that can create a place for it to break.My thought is, why reinvent the wheel, just do it like they did it.Birken
Reply:Why are you welding it around there?
Reply:Not been here long.. But zapster has played with some horse power.
Reply:Originally Posted by RIVERRATNot been here long.. But zapster has played with some horse power.
Reply:I am new to this forum, I could give you all some history but I will spare you the boring details. For those of you on the miller forum , I am Dan on that one, same guy but had to add the M because Dan Was taken here.  Anyhow.  The housings as mentioned are usually cast steel and require no real trick to weld. Preheat wont ever hurt you because if nothing else it does burn some of the crap out of the metal. Also as mentioned the tubes are generally just plug welded, and if done correctly they wont spin in the housing. They dont weld around because they are not always "shrunk" in, sometimes just a tight fit to light press where they stand the chance of pulling pretty bad if welded around. A lot of good tac welds around may save this from happening. I was building jeeps and building axles years back and spun up a couple plugs to put in the housing and one in each end of the tubes. The plugs were bored out to slide a piece of 1-1/4" stress proof through to line it all up and keep it straight. I am not an expert on this subject but have been there done that and thought I could give my .02.Dan.Repair Specialties LLC