I'm looking for the best way to weld up the front 44 in an EB. We'll be using a stick welder. I searched, and found lots of conflicting info. Anybody with actual experience care to chime in as to the best method, as well as the best rod to use. Thanks.

Are you talking about the spider gears or the pumkin?

Spider gears, ala lincoln locker.

Here's a link

http://www.pirate4x4.com/forum/showthread.php?s=&threadid=39735&highlight=7018

hmm first I wouldn't weld the front axle except in a straight mud toy, makes steering a bitch. if you are determined I have had good luck with 7018, just clean it up really well, tack the spiders in place really qwick (I use a 6011 tack on each side of the side gears) remove the carrier and go to it. cover the bearings when you do this to avoid getting slag in em.
I've done this on my 14 bolt with 44's and I havn't broke it yet. (I havn't gone far though) I also ran my old willies like this for two years no problems.
oh yeah definitly weld the gears to the case and to each other if possible, the more weld surface the better, and let it cool between welds.

I wouldn't weld the gears to the case, just weld the sidegears to the spiders and fill the gap between the gears real good. I don't see much difference in the diferent rods for a job like this. I don't know why you would need to tack weld anything, Just pull it out of the pig clean it and weld it. Clean it real good afterwards.

tack weld the side gears in place with the shafts in to make sure they line up when you are done. if you pull the shafts you can spin the gears out of place easy. you can check it on the bench of course this way just seems more foolproof to me.
why would you not weld it to the case? be a bastard to remove after it was welded and the carrier is only $35 for a dana44 anyways?

I've been running a welded front (Toy 8")for about 7 months but was in the rear first. It's only hard to steer when stopped, if I am crawling I'm fine. I just have to rock it if stopped, no biggy. I welded it with 7018. Welded the spiders to each other then the sides to the carrier, with many passes there. I don't know if this was the
"right" way but it has held up for me. I just did a another one with a Millermatic 210, ALOT less clean up comparred to stick. That slag took forever to chip out. Have fun.