Ok all you master welders, Need a bit of advice. i am going to 3-link the front of my TJ and will be welding a bracket to my HP D60. I know I need to preheat the diff. but what rod should i use or would it be better to tig. If tig is the way, what filler rod?
Any help would be greatly appreciated as this will be critical for my front end.
JM

Stick with high nickel

I have had good luck with using my mig, 3 passes

Ni99

./

I was under the impression Ni99 was used primarily for cast iron. If it's a Superdoody D60 then it's cast steel which is more dense than cast iron which wouldn't necessitate the Ni99 rod. Either way, hit up the search, there's a whole lot of information regarding this from what rod, how to weld it, how hot, how long, ect.

haz mat, I am a structural union welder, soooo here's How I would weld it, (with out knowing what type of steel your tabs are made of,, assuming mild steel)..... Run and up hill root with 6010, (either 3/32 or 1/8 rod) then cap it off with nice 7018,,,, that weld will never break, preheat if you want to ( i wouldn't as up hill puts a lot of heat in and wouldn't want to risk any warping), around 100-120 amps for the up hill welds,,, If you want a real smooth looking finish you can run tig over it as a cap weld and make it look real slick,,, thats how weld pipe/plate that needs to have a visual insp also.
there my 2 cents

thanks for the info.
hm

haz mat, I am a structural union welder, soooo here's How I would weld it, (with out knowing what type of steel your tabs are made of,, assuming mild steel)..... Run and up hill root with 6010, (either 3/32 or 1/8 rod) then cap it off with nice 7018,,,, that weld will never break, preheat if you want to ( i wouldn't as up hill puts a lot of heat in and wouldn't want to risk any warping), around 100-120 amps for the up hill welds,,, If you want a real smooth looking finish you can run tig over it as a cap weld and make it look real slick,,, thats how weld pipe/plate that needs to have a visual insp also.
there my 2 cents

now thats a master welder

Ok all you master welders, Need a bit of advice. i am going to 3-link the front of my TJ and will be welding a bracket to my HP D60. I know I need to preheat the diff. but what rod should i use or would it be better to tig. If tig is the way, what filler rod?
Any help would be greatly appreciated as this will be critical for my front end.
JM

Typically, if two passes with a Mig, one hot fast root and a nice lower heat slower cover pass won't hold it, it's beyond your abilities and you need to get a real weldor in there to fix your fuck up. It's about that basic.

Clean the rust off really well and then take a propane or Mapp torch to it to warm it up and drive out the moisture. After that, get after it and it will either work, or you need a weldor.

Royal XJ, the next time my forman fusses at me I tell him you said I was a master welder ,hahahaha maybe he will leave me be lol

Royal XJ, the next time my forman fusses at me I tell him you said I was a master welder ,hahahaha maybe he will leave me be lol

A master weldor would know that a welder is the machine and the weldor is the person. :flipoff2:

I was under the impression Ni99 was used primarily for cast iron. If it's a Superdoody D60 then it's cast steel which is more dense than cast iron which wouldn't necessitate the Ni99 rod. Either way, hit up the search, there's a whole lot of information regarding this from what rod, how to weld it, how hot, how long, ect.

Who told you D60 centers were cast steel? I assure you, they're not. I personally have a 02' SD D60 and it has cast steel inner C's and knuckles, but not the center section.

http://www.4wheeloffroad.com/techarticles/drivetrain/131_0906_dana_super_60_front_axle/photo_03.html

Read the first 3 words in the picture caption.

Also, check the Ballistic forum. There is a Balljoint buildup write up in there...confirming its cast iron and a good writeup on fabbing it.

Whichever way you do the repair post what you did and how it worked out.

Look, You can go 6011 or 6010 capped with 7018 or 10018 if you want to but just know that it's not going to the moon. I've been a welder for more years than I care to mention and it really bothers me to see people overkill their work with a weld. To me it's a sign of inexpieriance. HEAR THIS>>> If you run 6010 then 7018 uphill you are almost setting yourself up for failure. With that kinda heat on metal thats aroun 1/4 to 3/8s thick at the most it will either move or get brittle. Take it for what its worth. I have welded really high pressure pipe for a long time and don't want to see a good D60 go to ruin with overkill welding.
I would 2 pass it with some good heat from a MIG and call it good. No need to preheat.

I would 2 pass it with some good heat from a MIG and call it good. No need to preheat.

I only do a mild preheat to drive the moisture out. But, I have also been in a place where it was pretty humid. As long as it's dry, I don't think it matters.

I only do a mild preheat to drive the moisture out. But, I have also been in a place where it was pretty humid. As long as it's dry, I don't think it matters.
Ya I live in OK where it's pretty dry for the most part. Good point on the preheat for humidity.