Re: Welding Dana 60 axle tubes
[Re: farmboy]
#2440602
01/25/18 04:21 PM
01/25/18 04:21 PM
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Joined: Dec 2005
Posts: 11,552 Fulton County, PA
CMcAllister
Mr. Helpful
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Mr. Helpful
Joined: Dec 2005
Posts: 11,552
Fulton County, PA
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Tig with ER70-S2. Clean it and then clean it some more. Use a torch to heat the joint and remove any remaining oil and contaminants. Heat the center section and keep it warm. Weld some, heat, weld some, heat. When it's done, use the heat to keep it warm and let it cool down gradually.
If the results don't match the theory, change the theory.
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Re: Welding Dana 60 axle tubes
[Re: farmboy]
#2440728
01/25/18 09:33 PM
01/25/18 09:33 PM
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Joined: Oct 2007
Posts: 4,206 New York
polyspheric
master
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master
Joined: Oct 2007
Posts: 4,206
New York
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All good. Shim it into the jig, and let it cool down there. Weld in opposing spots as if torquing wheel lugs: 12 o'clock, then 6, then 11, then 5 (not in clock rotation).
Boffin Emeritus
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Re: Welding Dana 60 axle tubes
[Re: farmboy]
#2440738
01/25/18 09:53 PM
01/25/18 09:53 PM
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Joined: Jan 2011
Posts: 4,785 Utah and Alaska
astjp2
master
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master
Joined: Jan 2011
Posts: 4,785
Utah and Alaska
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Get it hot tanked first, then you need a welder that puts out a lot of heat. Any of the 70 series rods and filler will work, it just depends on what you are comfortable with. Tim
1941 Taylorcraft 1968 Charger 1994 Wrangler 1998 Wrangler 2008 Kia Rio 2017 Jetta
I didn't do 4 years and 9 months of Graduate School to be called Mister!
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Re: Welding Dana 60 axle tubes
[Re: astjp2]
#2440947
01/26/18 12:54 PM
01/26/18 12:54 PM
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Joined: Sep 2003
Posts: 19,396 north of coder
moparx
"Butt Crack Bob"
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"Butt Crack Bob"
Joined: Sep 2003
Posts: 19,396
north of coder
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i have only narrowed a few rears, but when the housing and brackets are done, i use a 2" diameter ground bar with steel pucks. 2 of which are bolted to the gear center bearing location. these have a .0015 id clearance for the bar to pass through. then the other 2 at the axle bearing location. they have .001 id clearance for the bar, and .002 od clearance for the bearing bore. i chain the housing to a piece of 12" I beam that has a very thick web and flanges. i test the axle bearing pucks for a super easy "slide in" fit with the round bar installed. if they don't just "flick" in using just tiny finger motion, i heat the housing and use a bottle jack to apply pressure to move the tube in the desired direction. let the tube cool, then try the puck. repeat as necessary until i have the puck fit to my satisfaction. let cool over night, then try puck fitment again. if satisfactory, then assemble rear and install. never had any tire wear, or tracking issues, doing this way of insuring housing was straight.
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Re: Welding Dana 60 axle tubes
[Re: farmboy]
#2441702
01/27/18 08:41 PM
01/27/18 08:41 PM
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Joined: Dec 2007
Posts: 391 kansas
farmboy
OP
enthusiast
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OP
enthusiast
Joined: Dec 2007
Posts: 391
kansas
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Thanks for the help, Think I will preheat and tig. Any particular reason to use -2 instead of -6 rod?
Last edited by farmboy; 01/27/18 08:43 PM.
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Re: Welding Dana 60 axle tubes
[Re: farmboy]
#2442239
01/28/18 02:44 PM
01/28/18 02:44 PM
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Joined: Dec 2004
Posts: 148 Albert Lea, MN
GTX5877
member
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member
Joined: Dec 2004
Posts: 148
Albert Lea, MN
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Tig welded many narrowed Danas and 12 bolts with nickle arc rod. Knock the flux off it and welded continuous around tube. Did the same as everyone else: grind the cast and the tube, preheat to burn out contaminants, and had it jigged with alignment bar. Let completely cool before removing bar. You can check your final alignment with how easy the pucks slide in and out of the housing ends. Nickle rod is designed for dissimilar metals. Good luck
1967 Dart GTS 426 Gen III Hemi 1968 Hemi Cuda 572 SS/AH Clone 1988 Chrysler LeBaron Coupe S/S 2003 Dodge Ram 1500 4dr SLT lowered 2012 Ram 1500 2wd Lowered 1970-1/2 Camaro Z-28 1974 VW Karman-Ghia
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Re: Welding Dana 60 axle tubes
[Re: farmboy]
#2447238
02/06/18 01:36 AM
02/06/18 01:36 AM
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Joined: Dec 2005
Posts: 11,552 Fulton County, PA
CMcAllister
Mr. Helpful
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Mr. Helpful
Joined: Dec 2005
Posts: 11,552
Fulton County, PA
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Thanks for the help, Think I will preheat and tig. Any particular reason to use -2 instead of -6 rod? -2 is typically used in TIG welding where the material is or should be very clean. -6 is usually used for MIG wire but is available in precut TIG wire also. -6 has a higher silicon content which helps pull impurities from the puddle when the material is slightly contaminated. Other than that they are pretty much the same. Some people like the -6 for TIGing. I use -2 since it is the most widely recommended for clean 4130 which is usually what I do. I don't do much "dirty" stuff. I would check the tubes with an alignment tool before welding it up, just to verify the thing is not bent before you do anything. While you can put the ends on to match the differential centerline, if they are way off, it creates all kinds of other goofy problems with the wheelbase being moved, etc. Mostly on sheetmetal housings, but I would still look at it.
If the results don't match the theory, change the theory.
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