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Old 07-01-2009, 02:23 PM
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Welding a rear brace on a ford 9 inch rear end

I purchased rear gusset brace for my ford 9 inch rear end. Its flange to flange. How do you weld this thing on without warping the tubes? I know it will want to pull the tubes towards the brace. I've heard people say weld it with a axle housing jig installed. However I don't see any place that sells them and I don't have machinery to make my own.

My only thoughts is to tack a brace on the front or opposite side of the brace to hold the tubes from pulling back when welding the real brace on the backside.

The I can weld the brace using my tig and space the welds out and allow proper cooling time...then come back and fill the gaps between the spacing of welds.

After everything is done I can cut off the tacked on brace on the front side and grind the welds smooth.

Any ideas if this will work?

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Old 07-01-2009, 03:18 PM
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I can't imagine welding the brace on it w/o having to straighten it afterwards. Even using a brace on the front to counter the rear brace- I still believe it will need to be straightened.

You could ask around and see if any of the driveline shops in your area (that do d-shafts, etc.) might have the capability to straighten it out afterwards.
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Old 07-01-2009, 03:56 PM
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That's alot of welding and heat. When I do them, I put the housing in a jig and still have to straighten the housing sometimes.
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Old 07-02-2009, 07:43 AM
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You'll need to find a shop to straighten it after. The last time I welded on a rear like that, the guy wanted me to leave the bar in it to keep it straight. I told him that won't work but he insisted so I did it just to show him. Problem was that I almost couldn't get my bar out afterwards! All welding should be done to the housing BEFORE welding on the bearing ends. If you do that last, you'll have good alignment. The only problem I see on the 9 might be is you'll open up the 'mouth' where the chunk bolts in but I don't think that will be much of one....
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Old 07-02-2009, 11:19 AM
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thanks for the advice guys. What if I did this instead? I will weld it without the jig so it doesn't get stuck. Then I can straighten it using this technique. I just found a buddy that can machine the parts for me.

Straightening a rear end housing
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