A properly prepped and executed rosette weld would be much stronger than the axle tube it was on. You really cant get the penetration into the sleeve that you need with a 110V harbor freight mig on 3 extension cords at the end of the driveway....

 

Welding tests will show the weld stronger than the original metal or the test fails. The strips are bent both directions (one strip to the root and the second to the weld) and the break happens away from the weld if it breaks.

 

Unsure why you guys are even arguing that as you can clearly see the weld didn't crack, it cracked the whole tube around the weld.

 

If the hole was not de-burred properly it can cause a micro fracture that can spread. On aircraft all holes are deburred just because of those issues. Anyone that works with metal on aircraft will tell you every rivet hole that is drilled is deburred.

 

I just went through a front housing replacement. I wouldn't replace stock with stock nor would I entertain putting another D30 in. The cost isn't going to be much more to upgrade. I just dropped in the Teraflex Tera44 for $3200 installed.

 

The cost is absolutely huge when compared to a $200 - MAX $500 d30 from Craigslist.

 

You should get a hemi

 

LS3 would be better. LOL

 

Seems like a good price. Where did you find that?

 

Insurance came through and wrote me a nice check. They are calling it collision. The agent had never seen anything like this broken Dana 30 of mine.

Now, on to axle shopping.

I want an aftermarket Dana 44 replacement for my factory Dana 30 and am looking at Tera Flex and Dynatrac.

I am considering having the ARB locker installed in the front while I am at it. Why not?

I'll need axle shafts but apparently I can re use the outer knuckles and brakes. Any suggestions on axle shafts? I am thinking 30 spline Ten Factory axles might be decent and fairly affordable.

Suggestions?