Dana 44 cracked plug welds

[Hagan]

How far is the drill stopping at? Your most likely stopping at the axle tube, its a much denser alloy than the weld. If you can, have someome with a 220 reweld it for you. Keep the other housing in case you decide later you want full width

It stops within like a 1/16" into drilling. I'm going to try another drill bit.

 

[SAY789]

Use your torch to heat it up if the new drill bit dont work anybetter. Heat will make it softer

 

[The Jester Race]

It stops within like a 1/16" into drilling. I'm going to try another drill bit.

Sharp bits, lots of lube, start small(1/8") and work your way larger.

-Jester

 

[Hagan]

Well I ended up using a drill press and the thing wouldn't cut into it. I then used a die grinder with a burr and it did alright but it broke the carbide burr. I've got 1 down and 12 to go!

I'll try the heat and new drill bits! Thanks guys!

 

[Sasquatch_Ryda]

Grind all your welds out and start over if you are at all concerned!

 

[Hagan]

Grind all your welds out and start over if you are at all concerned!

Do you REALLY think this is necessary? To grind the welds out and start all over again?

 

[Sasquatch_Ryda]

I was talking about the plug welds.

 

[Hagan]

Yeah I know what you meant. But how necessary do you think this is?

 

[Hagan]

Well I think I am going to just junk both of these housings.

And I called to get a quote on welding plug welds and they said they no longer weld plug welds for front axles and can only do rear axles? I'm so confused now.

 

[The Jester Race]

Well I think I am going to just junk both of these housings.

And I called to get a quote on welding plug welds and they said they no longer weld plug welds for front axles and can only do rear axles? I'm so confused now. Seems like a piece of shit company to me. What I'm asking to do has been done thousands of times but everyone acts like what I'm doing has never been done before.

No need to junk the housing just cause of cracked plug welds. Just drill out as much as you can and burn them nice and hot. And then burn around the tubes too if your that worried about it. And if you still dont think that's enough, truss it.

- Jester

 

[SAY789]

Ya man dont junk em for that reason alone. Otherwise ill have to come up and rob your scrap bin lol. I know several shops down here that would weld those up no problem no questions asked if need be

 

[legoms013]

Well I think I am going to just junk both of these housings.

And I called to get a quote on welding plug welds and they said they no longer weld plug welds for front axles and can only do rear axles? I'm so confused now.

That mechanic is an idiot....

 

[SAY789]

Ya tell him its a rear steer high pinion reverse rotation that should get him to believe ya

 

[Hagan]

Yeah it was actually Dutchman axles that told me that. That's the place I got my axle shaft shortened, and they messed up the measurements the first time and sent me a replacement. I thought I had to grind or drill out the whole weld.

I found a '77 Dana 44 complete for $150. I'm getting it tomorrow. I have to buy hubs and a stub shaft (for 78/79 axle) and that is the price of this axle alone. I am actually seriously considering doing a full width but I don't think its worth the hassle.

I was having a heck of a time grinding or drilling the old plug welds out. I guess I'll make a decision tomorrow and what I want to do. But for $150 its hard to pass up.

 

[SAY789]

Full width is nice even on the road. When i was running 15x10 3.5bs wheels on my dana 35 i was wider then than i am now with my 38's and full width. So what are you doing with the 2 housings now?