craig1010cc
Club Retro Rides Member
Posts: 2,993
Club RR Member Number: 35
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advice on welding diffscraig1010cc
@craig1010cc
Club Retro Rides Member 35
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Jun 11, 2010 19:04:59 GMT
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Not wishing to start a debate on the sensibleness of a welded diff, but if you where to convert an open diff to a fixed one,
what is the minimum rating of MIG that you should use?
what is the best way to get the gears clean enough to take a good weld?
Should the diff be stripped out of the casing or is it fine just taking the back cover off?
Any other tips for a 1st time diff welder (I'm used to welding panels and tubing only)
for reference, its for my 91 Eunos
Cheers
Craig
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Jun 11, 2010 19:39:28 GMT
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take the back cover off, clean it as best you can and stick a big bolt in and weld away, will save loads of wire by using the bolt  |
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rob0r
East of England
Posts: 2,743
Club RR Member Number: 104
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advice on welding diffsrob0r
@rob0r
Club Retro Rides Member 104
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Jun 11, 2010 20:09:21 GMT
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I grind down thick metal plates to fit flush inbetween the gears, then get my main man Bodieandoyle to flash his welder across it. Back plate off and it will help if it's off the car.
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E30 320i 3.5 - E23 730 - E3 3.0si - E21 316 M42 - E32 750i
ETC
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stealthstylz
Club Retro Rides Member
Posts: 14,842
Club RR Member Number: 174
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advice on welding diffsstealthstylz
@stealthstylz
Club Retro Rides Member 174
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Jun 11, 2010 20:32:12 GMT
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I blast a load of brake cleaner in then get a blowtorch in there to burn the rest off, then do as rob0r says. Put plenty of weld on I reckon 150amp might do it turned up full whack. My welder is 190amp and that on full whack seems fine.
Matt
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Jun 11, 2010 20:39:37 GMT
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then get my main man Bodieandoyle to flash his welder across it. that'd be me then  I use a lincoln minimig 180 on almost full bore. A good dousing of anti spatter in there first and then if you want to be really neat then power wash it after and immediatly fill with oil. Last time I done that, I used a hot air gun on low for half an hour to dry it out first. I was being really pro with that one ;D On the bench is soooooo much easier than on the car |
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craig1010cc
Club Retro Rides Member
Posts: 2,993
Club RR Member Number: 35
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advice on welding diffscraig1010cc
@craig1010cc
Club Retro Rides Member 35
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Jun 11, 2010 20:58:12 GMT
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So my 135 amp turbo mig isn't really man enough for the job then is it. Oh well, will have to find someone local with something a bit more manly  The diff will be off the car, mines got a viscous diff at the min and looking at getting a welded diff to try out (only about 14 bolts to change it over so easy enough) |
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Chops
Club Retro Rides Member
Don't touch me I've been somewhere
Posts: 454
Club RR Member Number: 36
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advice on welding diffsChops
@exodore
Club Retro Rides Member 36
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I steam cleaned it out first to make sure it was oil free then cut 2 bits of 1/4" plate (one for each side) to bridge between the gears. I use 180 amp Sealey Supermig tured up to about 3/4. Anyway, this thread needs pics............ this is a merc diff i did recently   |
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Last Edit: Jun 12, 2010 0:16:38 GMT by Chops
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So my 135 amp turbo mig isn't really man enough for the job then is it. Oh well, will have to find someone local with something a bit more manly Bring it over to A52 next weekend (18th > 20th) and we can get this sorted for you. The welder is 215a so should be upto the job |
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rtlkyuubi
Posted a lot
Low and Slow
Posts: 2,922
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Jun 12, 2010 10:04:27 GMT
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Yea, get a good welder (like Bruce's ;D) to weld it or you'll have problems like mine: Its not fun having to remove bits of metal thats jammed your diff at 2am   Opps ;D This was the 2nd time it broke  So I finally took it to work and used their neuclear spec welder:  |
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craig1010cc
Club Retro Rides Member
Posts: 2,993
Club RR Member Number: 35
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advice on welding diffscraig1010cc
@craig1010cc
Club Retro Rides Member 35
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Jun 12, 2010 10:14:29 GMT
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Bring it over to A52 next weekend (18th > 20th) and we can get this sorted for you. The welder is 215a so should be upto the job If Ican get one posted to me by then I might take you up on that kind offer Bruce ;D |
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Jun 12, 2010 15:55:33 GMT
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We have done around 16 diffs now, all been thoroughly tested at Santa Pod DWYB days and not one failed. We remove from diff unit from te car, clean out in Jizer tank and then clean out with brake cleaner. Brake cleaner is explosive so make sure you burn it all out before welding. Clean up the edge of the area to be welded with a die grinder and also where the earth wire is attached. Fill the hole where the planet gears are with weld on a high setting. Turn throught 180 degrees and do the same on the other side. Make sure you weld the planet gears together. Allow to cool, refit cover and diff unit to car. We use a thick gear oil, usually 85w/140. Broken a few half shafts but no diffs.
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