So I'm in the middle of my axle swap now, and I'm to the point where I need to decide whether to weld the tubes or not. I'm not going to be doing much rock climbing at all, since I'm in Michigan. The only place to do any is at a private off road park, and its not too hardcore at all. I just do the usual trail and dune riding. Are the factory plug welds enough, or do I need to weld the tubes, too? I'll be running the 4.0l and 35s, so it shouldn't stress the axle too much.
See, I've been researching this everywhere and the majority say use a stick welder and 7018 rod. The thing is, I can't weld well enough to not warp the tubes. And I know some guys that probably can, but I really don't want them to warp, because then I'm screwed. I do want them welded though.
Im not a pro welder or anything but most people over think this. Think of it this way, the tubes are pressed in the center section which gives them the horizontal strength. You are not going to increase that strength by welding the tube to the center section. We are simply putting a bead that connects the center section to the tube to keep them from turning where they are pressed in. Weld a 1/2" tack on one tube then go to the outherside and weld the same tack, rotate 180 degrees and do the same thing. Continue till the whole thing has a weld completely around the tubes. I then made a single pass to dress it all up.
$ Quality isn't expensive, it's priceless! $
94 YJ, 2.5l, BD 1" mml, sye, 4.5" rubicon express extreme duty, 1.5" shackles, 1" bl, dana 30-4.88 and lockright, 8.8- 4.88 and spartan, tera low 2wd, 35" km2's, custom cage and rock sliders, ramsey pro 6000 winch....
Alright, I've talked to a few buddies and have access to everything except tig, so what would be best to use, and what rod/wire? And do I need to preheat the cast diff, or just go at it cold? Sorry for all the questions, I'm not a welder.