I’m not too far from adding an axle truss, c gussets will be added when I replace my ball joints next week.

I’ve seen videos of them installed with the axle removed and gutted, Quadratec also has a video showing it can be done with the axle installed and full of oil and they say that preheating the diff housing is optional.

Is one way better than the other? Can someone shed light on this? I don’t have any issue pulling and gutting the axle, and heating the diff housing... but if it’s really not necessary then I would rather not add the extra work.

 

It can be welded in with the axle installed, but do you have the ability or experience to lay a solid bead overhead?

When I did mine I simply pulled the axle and put it on jack stands so I could rotate the axle around as I burned everything in. I capped off the diff vent with a plug in my garage that happened to fit perfectly. Didn't drain the diff. It was summertime when I did mine, so it was around 80-85 degrees outside. Didn't preheat the diff with a torch, but if it was cooler out or in your garage...I'd preheat. I did not wrap the axle in a heat blanket while the welds on my diff cooled off, and none of my welds popped.

If I were you I'd pull the axle and throw it on jack stands. Plug the diff vent with tape or cut down wine cork. Burn the truss and gussets on, paint the axle, install new BJ's, and put the axle back in.

 

I’m not exactly a stellar welder but I have a decent machine and with a few minutes of practice on equivalent material, I can lay a decent bead. I use my welder about once a year so I’m not very practiced these days. It the angles are weird then maybe I should remove the axle at least. As far as preheating and cooling, is it best practice or overkill to do that? Also, if I preheat, should I gut my axle to avoid cooking seals or fluids?

 

I'd recommend pulling the axle so you can get on top of it, or whatever angle you can lay your best bead. What welder are you using?

It's most definitely best practice to preheat and wrap in an insulating blanket, and allow it to cool slowly for 1-2 hours (some people say 24 hours, but thats overkill). If you hear a click or pop, one of your welds separated. I'd recommend preheat and wrap, but just know that I and others have gotten away without it.

Also, I forgot to mention this but this isn't a quick process. Fitting the truss will take you a decent amount of time with and angle grinder and lots of test fitting. You'll also want to take your time with the stitch welds and switching sides while allowing your welds to cool.

 

I have a Hobart 195. So I’ll have the power and it’s a decent setup. As far as taking my time and working small areas while allowing it to cool is something I planned since that’s the one consistent thing I’ve seen in all the tutorials.

I figured there will be some small areas of grinding on the truss to get it to fit. Nothing with metal is quick and easy so I wouldn’t try and fool myself. Haha.

so if I weld it on a higher heat setting on the welder will I be safe to not preheat with a torch or did you use a setting for 1/4” plate?

 

I got a good chunk of the welding done yesterday and wrapped everything up in a blanket. I’m waiting on the track bar bracket which will come in today. I think the welds are decent minus one goober weld spot which looks gooberish but I feel it will hold. I have another line to weld on the cast but I ran out of propane. Here’s where it sits as of now.

 

What wire did you use? Flux or argon gas?

 

I used .030 wire with 75/25 gas.

 

following..

 

ok I showed this to my neighbor who is a certified pipeline welder with about 40 years experience and he said no. He is not a jeep guy or a car guy just a welder guy who welded for a living. He first said to get a good weld you need to really prep the area and have clean metal and he said that was not done here and he said it looks like poor penetration and that gas shielding was not properly done and a bunch of other stuff but bottom line he said he could easily see those welds not holding under any kind of stress. I hope he is wrong and it lasts and holds up to whatever abuse you put it thru.