Welding axle tubes

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I picked up a Ford 8.8 rear axle to drop in my '93 Jeep YJ project, and I plan on welding the axle tubes to the center differential housing.  I'm pretty sure the tubes are regular steel, and I believe the diff housing is cast steel.  What would be the best way to weld these together, MIG, TIG, or stick?
Reply:Years ago we had a 10 second drag car. I welded them up with hi alloy 500. Don't know if you need anything that strong but we never had any problems.
Reply:Why do you need to weld the tubes to the diff housing? Are you narrowing the axle or something? Regardless, cast steel is not something easily welded with anything.
Reply:I have always stick welded these, but the factory welds will be wire feed. As far as what process you should be using, it should depend on the quality or the equipmentyou have available, as well as your skill level with each process. I definitely wouldn't perform this mod. with a 110 volt wirefeed. Properly prepped, the job could be done with any process.  Good luck!
Reply:I have welded 1 of these with mig solid core wire using a millermatic 250 and never had any problems this was on an f150 on 35" tires and my brother-in-law tig welded mine on my mustang with no issues. I don't think it is real critical I know lots of racers that just mig weld them and never look back, but I'm sure others will chime in.
Reply:Thanks for the information.  I don't think its really necessary for my build, as I don't plan on running anything over 32" tires.  But, considering I am going through the trouble of welding up new spring plates and perches, there's really no reason not to go ahead and weld them.  Plus, its much easier to do it now while the axle is in the shop on stands and not under the Jeep.  I have a Lincoln Power MIG 255 and an Invertec v-250s stick/TIG, so amperage shouldn't be a problem.  I was just curious if .045 solid wire will be sufficient for the type of metal being used.
Reply:If it's not necessary then don't do it.
Reply:make sure you use an alignment jig to keep the axles true. I seem a few jigs on e-bay and I think there is some one on pirate4x4.com selling the jigs as wellAdam MMorales Ranch
Reply:If it's not necessary then don't do it.
Reply:I welded mine with a mig, I ran 36" IROK radials, electric locker and wheeled the crap out of it and never had an issue. I also had 4.88 gears. I don't drive it like i stole it but i do hit it when needed. Stock i6, efi with a 5 spd.(wrangler)
Reply:Dave,What kind of prep did you do before welding?  Did you drain the diff oil, or do you think enough heat is transferred to cause any problems?
Reply:I'm pretty sure 8.8's are cast steel pumpkins. Mustang guys weld them all the time using either MIG or stick. To keep it from warping you need to keep the shrinkage the same on opposite sides of each joint. I'd weld it in two sessions. I'd weld 3:00 to 6:00 stopping at 6:00. Then immediately weld 9:00 to 12:00 stopping at 12:00. I'd let it cool about 1/2 hour then finish the welds, again with the stopping points opposite of each other. You should also weld out the two factory plugs that hold the axles in place. I'd drain the gear lube and even stand the axle up if its a option.Last edited by Gus_Mahn; 04-05-2011 at 09:27 PM.
Reply:Its cast steel not cast iron. I have welded with my mig no problem. Preheat couldnt hurt either, but I didnt on the last one I did. No problems....HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:Curious… I am just thinking out loud…Do you think that it is necessary to weld the whole circumference of the tube.  Why not two or three evenly spaced one inch welds?IMHO: I would pre-heat the pumpkin.
Reply:I am just thinking out loud…Do you think that it is necessary to weld the whole circumference of the tube. Why not two or three evenly spaced one inch welds?
Reply:i welded the tubes on my Sterling 10.25. When I did it, I took a torch and went around the tubes where you want to weld to burn out contaminates, then turn up the mig and weld away. I just single passed it, Im sure you could lay a root and a 2 bead cover if you wanted. You aren't drag racing or nothing, so it isnt super critical.
Reply:Originally Posted by Jason280Any weld will be an improvement over the pressed in plugs, and I believe two or three 1" beads would certainly be effective.