Been sitting on my Evo gussetts for a few weeks trying to figure out how to handle the install. I spoke to a couple guys about having them welded and seems like its going to be a $300 job, give or take.

I also saw a thread on here where a guy modded and chopped a 3/16" thick bumper with a $90 harbor freight welder. The description says "CHICAGO ELECTRIC WELDING SYSTEMS Weld material from 18 gauge to 1/2" thick with this flux wire welder."

Harbor freight is about 1 mile from here. Am I crazy for thinking what I am thinking, that I can just DIY this job with this welder? If the welder will work I can probably do the job and then flip the welder to a friend for $50, so save a huge chunk of change towards the ace sliders I have been wanting...

 

I don't know how much of a PITA it is, however something like this i would get done professionally.

 

If you are a very experienced welder you might be able to make a $90 welder work, but it would be slow going and you may cook your ball joints. The first trick would be to see if the welder actually works out of the box! I am pretty wary of anything electrical from HF.

 

Whenever you do it remember you have to remove your ball joints. The shop here charged me 120 to install all c's, control arm skid and to install my anti-rock.

 

I have a career in welding field. $300 out of a busy or well known shop seems to be ehhhh we bit high. The problem with cheap welders( especially a little FLUX CORED wire fead welder) is they don't weld hot enough for the abuse of gussets. If you buy a 90 dollar welder and weld it ur self.... They WILL break due to being to cold of a weld. Depending on the shop you go to, they have larger 220 or 480 type welders and weld hotter deeper weld and can handle the abuse of jeep flex. Save ur $90 for the larger $300 job.
Just my 2cents

 

A big chunk of that charge may be them removing the balljoints. To save a little money, check out the mobil welding guys that will come to you. That way you can pull the bj's and do whatever prep you need to and all they will have to do is the actual welding.

 

I have a second vehicle so this may Not work for you, but I am gonna remove the whole axle, ball joints, axle shafts, drain the fluid, and give the whole thing to a shop to weld. This way I know its done right with a 480 welder, my ball joints wont be ruined, and he can do it on his time (thus charging me less). Just a thought...

 

Did mind a few weeks ago,got lazy and left ball joints in,but took my time,allowing time for cool down

 

The OP is in Florida, so it might be worth a PM to Off-Road Evolution. They appear to have associate companies that provide "and" install their equipment.

I'm in San Diego, so yesterday, I drove to Fullerton, and had ORE install the gussets, and the axle sleeves. Total price, out the door was $737. Looking at the receipt, the cost for welding the gussets was $190.

Hope this is good information.

edit: forgot to mention that they welded the gussets in place, using wet rags to keep the temp. down on the ball-joints.

 

You don't have to remove the ball joints to weld the gussets on. Just have plenty of rags soaked in water to cool the joints (swap rags often). The 90 dollar HF welders work great for small projects but I wouldn't recommend it on this type of work. You will need good penetration and I honestly don't think you'll achieve that with a 110.