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Old 10-17-2002, 08:21 PM
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Post Jig for welding a rear end

I would like to pick your brains for a good jig to
weld up a rear end. I have some ideas, but I like to hear what others have made and what works for
you. I am going to shorten several different lengths so it must be adjustable. Send your ideas
to ryan.orr@att.net.
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Old 10-17-2002, 11:53 PM
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  • 2 inch ground round shafting (superior shafting) long enough to have a foot sticking out each end.
  • Fabricated bushings that fit into the bearing ends, this maintains alignment of the axle bearings.
  • Common sense and good welding practice, Tig is preferable...stick is strong but warps slightly more. Getting the ends square for welding and the housing ends square can be done with a heavy file after being saw cut, roughing to the line can be done with an angle grinder. Proper prep of the weld groove is important to develop maximum strength from the weld.
  • A jumbo narrow set of vee blocks for aligning the housing and tacking into place. If you want to get real accurate you can make bushings for the center housing to ensure perfect axle alignment by fitting into the differential main caps.

Having a couple of strong buddies helps too.
“She may not look like much, but she's got it where it counts, kid. I've made a lot of special modifications myself.”

— Han Solo
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