Axle tube welding

[Stangman]

I'm a good welder, but I hear that the axle tubes on an 8.8 have to be welded on a jig...

I can't get away with welding them right there on the floor of my garage??

If not, whats this fancy jig look like so I can make one?

The tubes are already held in place, I cant just run short beads around every couple inches then go back and connect them so the tubes dont get too hot?

I just can't see spending big money paying someone for 2 circles.

[bobtsgt]

I did the 83s on a axle stand that Dave made. Did small little beads all around it concentrating the heat on the cast more then the tubes. The jig is the correct way to do it but if you don't have the cash and aren't scared its doable. Just don't put the heat on one side too much or else the tube may move inside the housing. The jig holds pressure against the tubes against the carrier and I also believe there are side holds that keep the tubes from moving once on a flat surface. You could make your own but by the time you figure it out and make one it may be quicker and easier to pay someone to do it.

[Stangman]

Wanna weld my rear end Bob? :D :lol:

[Gearhead559]

i need to get a jig...changing tube ends and shorting alot here lately...kind of getting old farming that stuff out..when i know it could be done in house...whats a jig run these days?

[7721Cobra]

Your supposed to preheat the cast too. Just save your money and have it done right. I tried welding mine at work, preheating and all. That housing is now in the scrap pile behind Aperacers shop.

[dsmawd350]

Anyone looking to have 9'' ends put on an 8.8 or axle tubes welded. as well as any narrowing Rigid Race Cars can do it. And cheaper than anyone else local, And is done the correct way TIG'd with nickel wire. shoot me a Pm and I can get you setup.

[bobtsgt]

Wanna weld my rear end Bob? :D :lol:

haha no time man. don't think i will be touching any cars for awhile. I'm sure you got a couple rear ends in your back yard. practice on one :lol:

[foxbodyfan]

Anyone looking to have 9'' ends put on an 8.8 or axle tubes welded. as well as any narrowing Rigid Race Cars can do it. And cheaper than anyone else local, And is done the correct way TIG'd with nickel wire. shoot me a Pm and I can get you setup.

East Fork Precision Welding662 Willow Street, Williamsburg, OH 45176-1032 (513) 724-7283‎

Shop change names?

[jlt2006]

haha no time man. don't think i will be touching any cars for awhile......

Dam Bob, it's only one child.:flipoff:

[bobtsgt]

Dam Bob, it's only one child.:flipoff:
hahaha yeah yeah I know. just gonna be awhile

[jlt2006]

okay, awhile

[Stangman]

I'm sure you got a couple rear ends in your back yard. practice on one :lol:

Nope sure dont. And I wont be payin the highway robbery price to get one done either.

[dsmawd350]

East Fork Precision Welding662 Willow Street, Williamsburg, OH 45176-1032 (513) 724-7283‎

Shop change names?

no. Thats the welding business up front.

[5.0calypso93lx]

Yea, Rob and Chad just welded the tubes and installed 9" ends and it turned out great. Good prices too.

Once you see the jig, you'll see why it's needed. I don't have much experience welding, but every seems to say that the tubes can move a bunch if you don't have ajig.

[Stangman]

Can someone show me a jig???

Once I see it I almost bet I can come up with a way to do it. on my own and on the cheap. Heck nickel wire can be bought. that's part of the equasion already.

[jlt2006]

IMO
I would be willing to bet that unless you plan to throw a whole shitload of horsepower and torque on a setup. You can easily get by with the do it yourself at home job. Besides if you weld an inch on one side of the tube then do a one inch weld on the oppisite side of the same tube, you should cause an equal reaction to each side. Thus equalling itself out.

All in all, I plan to do this myself and when it twists and turns and the world comes to an end. I will let you know what happens. See you at the track.

I am sure that they did this back in the day and all was fine.

[Maximus]

Can someone show me a jig???

Once I see it I almost bet I can come up with a way to do it. on my own and on the cheap. Heck nickel wire can be bought. that's part of the equasion already.

There are pictures in my Facebook account in my signature.

LMK if you can build a jig for less than $200 and weld the ends on. Id like to see it.:bigthumb

[Stangman]

IMO
I would be willing to bet that unless you plan to throw a whole shitload of horsepower and torque on a setup. You can easily get by with the do it yourself at home job. Besides if you weld an inch on one side of the tube then do a one inch weld on the oppisite side of the same tube, you should cause an equal reaction to each side. Thus equalling itself out.

All in all, I plan to do this myself and when it twists and turns and the world comes to an end. I will let you know what happens. See you at the track.

I am sure that they did this back in the day and all was fine.

thats exactly how I feel about it.


There are pictures in my Facebook account in my signature.

LMK if you can build a jig for less than $200 and weld the ends on. Id like to see it.:bigthumb


I'll let you know buddy! BTW I need some parts! I'll send ya a PM

[cobrajoe]

There are pictures in my Facebook account in my signature.

Some of us are STILL waiting to be approved/accepted/christened/blessed etc etc. so we can even see those pics. Cracker! :lol:
Oh and go become a fan!

http://www.facebook.com/pages/Racers-For-Autism/321047866784

[Rob]

Can someone show me a jig???

Once I see it I almost bet I can come up with a way to do it. on my own and on the cheap. Heck nickel wire can be bought. that's part of the equasion already.

Just so you know the correct nickel wire we use to do them is over $60 per half a pound.....and by the time you get done trying to build your own jig youll have more in time and material than it's worth unless you plan on doing quite a few. Not to mention every 8.8 we've worked on comes into the shop already tweaked from years of abuse. so even welding equally around the tubes is going to keep it out of whack. With the proper jig we can heat the tubes in areas and get everything back perfectly in square

[dsmawd350]

here's a few pics

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42790

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42789

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42788

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42787

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42786

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42785

[Stangman]

That looks amazing!! Jeeze... all that work and all I need is just some lousy tubes welded... that work must have been pricey!!

[RIXXX93GT]

I made a jig for Dayton Perf. Its not cheap if done right. Building a jig to do one housing is cost prohibitive.

[outlaw85]

I also made a fixture at work to do ours when Derek (AKA WAMS) destroyed his last year. It's alot of work and cost in materials to do this right let alone half ass! Guys spend the money and do it right the first time. $200.00 to disassemble, clean, straighten, pre-heat, and weld is a very fair price. I also use 309L Stainless tig wire it really works well also but it isn't cheap either.

[dsmawd350]

for those wondering why they cant just weld around the tubes and hope it all stays straight. Well because even after welding evenly the tubes are already not straight from the years of abuse.

Here are some pics of jesse's rear end with the jig in place before any work. As you can see the tubes are bent pretty good

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42882
http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42883

[jlt2006]

So that is ONE straight bar that is long enough to go through the rear end to end completely? Or is it just six inches long stuck in there, which would make it look bent all to hell.

Then you twist the angle with the camera to make it look three times worse than it is. Are you in sales?



for those wondering why they cant just weld around the tubes and hope it all stays straight. Well because even after welding evenly the tubes are already not straight from the years of abuse.

Here are some pics of jesse's rear end with the jig in place before any work. As you can see the tubes are bent pretty good

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42882
http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42883

[cobrajoe]

oh boy!:popcorn:

[Stangman]

So that is ONE straight bar that is long enough to go through the rear end to end completely? Or is it just six inches long stuck in there, which would make it look bent all to hell.

Then you twist the angle with the camera to make it look three times worse than it is. Are you in sales?

That is actually 1 long bar that goes alllllll the way thru... I was quite amazed with what is actually involved with in JUST doing the axle tubes...

Plus... that is a 220K+ rear axle...

[jlt2006]

That is actually 1 long bar that goes alllllll the way thru... I was quite amazed with what is actually involved with in JUST doing the axle tubes...

Plus... that is a 220K+ rear axle...

Thanks for letting me know. I did not think they are that bad, but I guess I was wrong. I had better check the one I have a little closer.

Thanks dsmawd350 for posting the pictures. I was a little skeptical.

[5.0calypso93lx]

So that is ONE straight bar that is long enough to go through the rear end to end completely? Or is it just six inches long stuck in there, which would make it look bent all to hell.

Then you twist the angle with the camera to make it look three times worse than it is. Are you in sales?

Nevermind....

[Stangman]

I probably should have fixed up my 65k mile rear end instead of this one. This axle has been beaten to death when it was in the old car I had. The car I think had been owned by every one in brown county atleast twice. But if this one comes out nice it will be worth it. I've got my 5 lug 31spline mosers, 31 spline carbon fiber trac lok diff. sitting around waiting to go in, and waiting on my 4.10's to get here and it'll be ready to go together! :D

[dsmawd350]

So that is ONE straight bar that is long enough to go through the rear end to end completely? Or is it just six inches long stuck in there, which would make it look bent all to hell.

Then you twist the angle with the camera to make it look three times worse than it is. Are you in sales?

:rolleyes:

Yes it is one straight solid bar that goes all the way through end to end and is centered by pucks held in under the diff caps.

like this ( but this is a 9'')

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42565

[jlt2006]

:rolleyes:

Yes it is one straight solid bar that goes all the way through end to end and is centered by pucks held in under the diff caps.

like this ( but this is a 9'')

http://www.ls1tech.com/forums/picture.php?albumid=13879&pictureid=42565

Thanks again for clarifing. I worked at Dana, Spicer Axle Division in Fort Wayne a few years ago and I would not have thought that they would get that far out of whack.

[RIXXX93GT]

The one I made is the same concept, get a straight long piece of SS or Tool steel (not cheap) custom make inserts to go in the diff bearing caps. Custom machine housing end retainers that the ends bolt to and slide onto the tool steel keeping everything in line and perpendicular to the axis of the diff caps. (All not cheap)