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Post by m201 on Jan 3, 2013 10:50:05 GMT 1
How did you line the three bits up before you welded them together please? ;D
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Post by muttleymk2 on Jan 3, 2013 16:24:20 GMT 1
I used a jig I borrowed from a guy who built axles for a living. It adjusted in and out to match the amount you wanted to cut out. He also cut down the half shafts and tig welded them for me, he used a laser and a lathe to make them dead straight. When I did the case I put an angle on both cut edges so I had a 2mm valley to weld up, this gave a really good weld which I had x rayed and we gas tested the case for integrity. I have done a few in the past, might build a jig of my own and start again
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Post by mk1andy on Jan 3, 2013 18:10:46 GMT 1
Did you take any pics when you were doing it Mutts?
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Post by m201 on Jan 3, 2013 18:49:50 GMT 1
I used a jig I borrowed from a guy who built axles for a living. It adjusted in and out to match the amount you wanted to cut out. He also cut down the half shafts and tig welded them for me, he used a laser and a lathe to make them dead straight. When I did the case I put an angle on both cut edges so I had a 2mm valley to weld up, this gave a really good weld which I had x rayed and we gas tested the case for integrity. I have done a few in the past, might build a jig of my own and start again Thanks Muttley, you are a very talented man aren't you.
When you say a 2mm gap, were the edges at right angles to the axle, or did you V them please?
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Post by muttleymk2 on Jan 3, 2013 20:25:25 GMT 1
No pics I'm afraid, was a long time ago, before digital cameras. Cut edges were beveled at 45 degrees to leave a valley for me to fill. You could make a jig for any axle but the shape of the axle tube dictates how much you can take out
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Post by m201 on Jan 3, 2013 20:41:43 GMT 1
No pics I'm afraid, was a long time ago, before digital cameras. Cut edges were beveled at 45 degrees to leave a valley for me to fill. You could make a jig for any axle but the shape of the axle tube dictates how much you can take out Thanks, yes, there must be a point where you end up mounting the hubs directly on to the diff. ;D
The 2mm you spoke of was ir at the bottom of the V then please Muttley?
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Post by muttleymk2 on Jan 3, 2013 20:53:08 GMT 1
Top, the bottom edges in the valley are touching. I made one run right round at the bottom and then two more side by side at the top. This gives full thickness penetration, also tweaked the gas right up to give a quality weld The axle tube shape has to be uniform for more than the amount you need to remove, otherwise the cut edges don't match up
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Post by m201 on Jan 3, 2013 21:16:30 GMT 1
Top, the bottom edges in the valley are touching. I made one run right round at the bottom and then two more side by side at the top. This gives full thickness penetration, also tweaked the gas right up to give a quality weld The axle tube shape has to be uniform for more than the amount you need to remove, otherwise the cut edges don't match up Duh, yes, of course, I never thought of that Muttley. Now I have thought about it, surely there are ways round it? Slingshots are very narrow.
Thanks for the info about your welding technique, it's filed away. Doubt if I will ever try my pigeon poo welding on an axle, but perhaps I will be able to use it to encourage someone to have a go.
In a previous reply, you spoke about making your own jig. Does that mean you will be able to pop higher ratio diff in Transit axles for people please Muttley?
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Post by muttleymk2 on Jan 4, 2013 20:20:56 GMT 1
Dragsters use purpose built axles nowadays, back in the day you had to mount a flange on the diff case to weld the tubes to. They don't have brakes on the outer ends either usually having transmission brakes of one sort or another. I wouldn't need a jig to just swap diffs
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