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.
02-06-2013 04:58 AM
Its not that hard and cheap insurance so why not. I used a 110v flux core welder to do mine. No special rods or anything needed.
02-06-2013 07:25 AM
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.
02-06-2013 03:47 PM
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.
02-07-2013 12:14 PM
mine are fluxed. just like bajonesy said in his last post.
02-07-2013 02:37 PM
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.
02-08-2013 10:13 AM
The center section is made of steel just like the tubes, you dont need to do anything or use any special welding equipment. Mig or stick for mild steel will work fine.
02-08-2013 04:05 PM
4 tacks then alternative slow stitches with cooling in between.