Popular Post Stellaghost Posted June 1, 2021 Author Popular Post Share Posted June 1, 2021 Started modifications to diff pinion today not complete as yet First clocked in Then started cutting New tip making a world of difference regards Stephen 5 Quote Link to comment Share on other sites More sharing options...
landroversforever Posted June 1, 2021 Share Posted June 1, 2021 What's the plan for aligning the two parts of the diff case Stephen? Machine yourself a temporary shaft to suit the bearings so you can feel how it turns whilst welding but also help with alignment? Quote Link to comment Share on other sites More sharing options...
Popular Post Stellaghost Posted June 1, 2021 Author Popular Post Share Posted June 1, 2021 30 minutes ago, landroversforever said: What's the plan for aligning the two parts of the diff case Stephen? Machine yourself a temporary shaft to suit the bearings so you can feel how it turns whilst welding but also help with alignment? No don't think I need to do that, my plan is to finish off the pinion shaft modifications and use that as the alignment tool, the shaft will be easy enough to protect from weld spatter so I will tighten up the taper bearings tight enough where it has clamped the two halves but still in a position to turn and check freedom of movement. I will support the "pinion clamp" with something a bit more substantial, maybe even hold it in my press until I'm satisfied the initial welds have fixed it into position. Then I can weld, test movement, weld etc until welding complete. I have had success with cast iron welding on smaller projects in the past with good results but, nothing as critical as this is going to be , but nothing ventured nothing gained regards Stephen 4 1 Quote Link to comment Share on other sites More sharing options...
landroversforever Posted June 1, 2021 Share Posted June 1, 2021 2 hours ago, Stellaghost said: No don't think I need to do that, my plan is to finish off the pinion shaft modifications and use that as the alignment tool, the shaft will be easy enough to protect from weld spatter so I will tighten up the taper bearings tight enough where it has clamped the two halves but still in a position to turn and check freedom of movement. I will support the "pinion clamp" with something a bit more substantial, maybe even hold it in my press until I'm satisfied the initial welds have fixed it into position. Then I can weld, test movement, weld etc until welding complete. I have had success with cast iron welding on smaller projects in the past with good results but, nothing as critical as this is going to be , but nothing ventured nothing gained regards Stephen Sounds like a good plan Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 2, 2021 Author Share Posted June 2, 2021 Bit more machining this morning and that's the lathe side of things done on the pinion Shaft down to completed size Removed and one of nuts put on and shaft re- clocked in with dti First cut of threads Threads complete and nut test fitted, very happy with the result as that's the first time I've cut threads on a lathe in anger so to speak, now I need to suss out cutting the splines in regards Stephen 3 1 Quote Link to comment Share on other sites More sharing options...
landroversforever Posted June 2, 2021 Share Posted June 2, 2021 It was always a bit daunting screw cutting stuff, but satisfying to see a pile of bolts stacking up once I got in the groove. Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 2, 2021 Author Share Posted June 2, 2021 (edited) So my vee block jig contraption is to big for bench top mill gonna have to get some smaller vee blocks That got me thinking I dont need splines in yet to set it up for welding so diff built back up seems to have gone back together ok up to now I'm thinking of cutting some steel and welding it to my work table and clamping down on cast sections of diff to leave shaft turning freely and be able to check it through the process, I'm also thinking if I clamp this into one corner of my bench I should be able to access all areas That's it for today need to track down some small vee blocks and more importantly feed the dogs regards Stephen Edited June 2, 2021 by Stellaghost 4 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 2, 2021 Share Posted June 2, 2021 Wow - that really shows how much length you’re taking out of it. 👏🏻 Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted June 2, 2021 Share Posted June 2, 2021 1 hour ago, Stellaghost said: So my vee block jig contraption is to big for bench top mill gonna have to get some smaller vee blocks --SNIP--- I see you use your workmate for chainsawing too 2 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 2, 2021 Author Share Posted June 2, 2021 35 minutes ago, CwazyWabbit said: I see you use your workmate for chainsawing too I certainly do, have a number of pieces of wood cut to size for replacements lol Regards Stephen 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 3, 2021 Author Share Posted June 3, 2021 (edited) @Anderzander Diff clamp!! Lol First some steel 5" channel and 30mm square bar drilled and tapped to m12 with my Ross wouldn't approve taps from Lidl Welded together Ran some m12 bolts down with die nut Welded onto my bench and diff clamped regards Stephen Edited June 3, 2021 by Stellaghost 4 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 3, 2021 Share Posted June 3, 2021 That looks solid enough !! Quote Link to comment Share on other sites More sharing options...
Popular Post Stellaghost Posted June 4, 2021 Author Popular Post Share Posted June 4, 2021 Cut some v sections out and checked with dti while rotating pinion, not a flicker on the dial, tack welded, pinion still turning fine so all good at the moment will take it out of clamp later to start welding fully as cast iron welding is best done with the rod as vertical as possible regards Stephen 5 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 4, 2021 Author Share Posted June 4, 2021 All v'd out and root welded now letting it cool down a bit then will take it out of clamp regards Stephen 1 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 4, 2021 Share Posted June 4, 2021 It seems like Dann only shared the picture a few days ago ... and here you are welding it up. Remarkable. 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 4, 2021 Author Share Posted June 4, 2021 (edited) Clamp release time The good news, it hasn't fallen apart, there is no obvious cracks and I can turn pinion by hand very happy regards Stephen just to add diff casting length is now 190mm it was 317mm regards Stephen Edited June 4, 2021 by Stellaghost Addition 4 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 4, 2021 Author Share Posted June 4, 2021 1 hour ago, Anderzander said: It seems like Dann only shared the picture a few days ago ... and here you are welding it up. Remarkable. A month on tuesday, had to have a go, there's always the danger I could have talked myself out of it lol Regards Stephen 1 Quote Link to comment Share on other sites More sharing options...
Wytze Posted June 4, 2021 Share Posted June 4, 2021 2 hours ago, Stellaghost said: Clamp release time The good news, it hasn't fallen apart, there is no obvious cracks and I can turn pinion by hand very happy regards Stephen just to add diff casting length is now 190mm it was 317mm regards Stephen Next step, clamping it up again and build up the weld? Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 4, 2021 Author Share Posted June 4, 2021 3 minutes ago, Wytze said: Next step, clamping it up again and build up the weld? Definitely build up the weld, but not clamping only doing short runs in different areas to keep heat down until all built up obviously testing rotation as I go regards Stephen Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted June 4, 2021 Share Posted June 4, 2021 Reckon you could end up with as much weight in rods as original casting at this rate 😉 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 4, 2021 Author Share Posted June 4, 2021 3 minutes ago, Bowie69 said: Reckon you could end up with as much weight in rods as original casting at this rate 😉 Sshhh don't tell Ross, he'll have a fit lol Regards Stephen 1 Quote Link to comment Share on other sites More sharing options...
miketomcat Posted June 5, 2021 Share Posted June 5, 2021 11 hours ago, Bowie69 said: Reckon you could end up with as much weight in rods as original casting at this rate 😉 Nah it's alright he cut a bit out to save weight..... Mike Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 5, 2021 Share Posted June 5, 2021 5” ! Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 (edited) 1 hour ago, Anderzander said: 5” ! 5" out of diff and 1 3/4" off pinion length, makes a hell of a difference to prop shaft length, a!so using modified front radius arms that are longer than trailing arms, so either axle or pivot end to alter also if it's axle I gain a bit more prop length regards Stephen Edited June 5, 2021 by Stellaghost 2 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 This welding up is taking a long time about two rods per half hour so the heat does not build up Also constantly moving diff to stop heat build up in one area along with altering diff angle to get optimum welding position Some thin walled pipe over shaft doing its job but so far so good no cracking regards Stephen 3 Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.