Welding Axle Tubes?

[hotrodrookie]

Im thinking about welding my axle tubes to the center section of the rear end (cast) What the best way to do this, i have tig, mig and stick. Filler rod? Pre/Post heat? Warping? The rear end is an 8.8 from a 98 explorer

[N2TRUX]

Anyone?

[hotrodrookie]

???

[69 longhorn]

You need a nickle fill rod to do that job(anything cast). Also , it should be preheated before welding. Probably your best bet will be your TIG setup, as you can control the heat better than with an old stick machine. I havent tryed welding the tubes to the center, so i cant comment on warpage. best of luck,crazyAL

[cajundragger]

weld slowww

keep it heated

use nickle

it will take ALOT of filler.

goodluck?

honestly if you dont have friends who have done it to show you exactly, I wouldnt do it.

[fixit-p]

Ni 55 is a good electrode for cast to mild steel. One thing you can absolutely count on is that the tubes are going to move so it would be a real good idea to fixture it up. Also weld short beads 1"-1-1/2" at a time one tube at a time after your first bead the second one should be directly opposite of it (the idea is that the second bead counteracts the tube movement of the first bead and so on). Preheat from 100 to 300 degrees use a heat stick which melts at preset temp (even heat very important no hot or cold spots) no post heat needed instead bury it in sand fill the case and tubes (I use kitty litter AKA ultrasorb absorbent) that ensures nice slow even cooling.

[tomtuna1978]

im not saying that i did this correctly ... but i just used my mig with .045 flux core wire, i stood the diff up vertically, and went slow welding 1-2in at a time and rotating a lot, i also pre heated it(helped a lot !!!) it took me a long time to find the right heat and speed setting on the machine( i started with a cold housing and once it started heating up my settings changed) so id suggest you play arround with a crappy/junk rear diff befor you weld up your good one ! and let it cool slowly !!!! ... good luck