landroversforever Posted June 5, 2021 Share Posted June 5, 2021 Are you doing one at a time to see how it goes or doing them side by side to split the heat/time? Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 Vee blocks arrived today so I can set up to do splines once finished welding and they're still too bloody tall For those of you with weak stomachs dont read on Nothing for it but to shave them and into the milling machine they go regards Stephen 1 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 5 minutes ago, landroversforever said: Are you doing one at a time to see how it goes or doing them side by side to split the heat/time? The other one is still in the front axle at the moment Ross, front prop is longer, will I need to modify, I dont know time will tell but if this one turns out like I'm hoping then yes I will most likely modify the front as well Only not doing them side by side so I only screw up one diff if it doesn't work regards Stephen Quote Link to comment Share on other sites More sharing options...
Bowie69 Posted June 5, 2021 Share Posted June 5, 2021 As you say, needs must! Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted June 5, 2021 Share Posted June 5, 2021 As an enthusiastic "armchair welder" why are you doing it in stages as opposed to bunging it in Madame's oven to preheat and then getting stuck in and finishing it? I understand your welding it in different paces to mitigate cracking and stresses by not building up too much heat, but why not dive in and get it done? Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 That's better clearance now, other one will need slightly less milled off as they are supporting different diameters on the same shaft regards Stephen Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 2 minutes ago, JohnnoK said: As an enthusiastic "armchair welder" why are you doing it in stages as opposed to bunging it in Madame's oven to preheat and then getting stuck in and finishing it? I understand your welding it in different paces to mitigate cracking and stresses by not building up too much heat, but why not dive in and get it done? Because there is two schools of thought, one hot and one cold I'm going with cold as I can check easily and constantly if I just go for it I'm totally screwed if the pinion then has tight spots at the moment slow and steady seems to be working regards Stephen Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 5, 2021 Author Share Posted June 5, 2021 (edited) 3 hours ago, JohnnoK said: As an enthusiastic "armchair welder" why are you doing it in stages as opposed to bunging it in Madame's oven to preheat and then getting stuck in and finishing it? I understand your welding it in different paces to mitigate cracking and stresses by not building up too much heat, but why not dive in and get it done? 3 hours ago, Stellaghost said: Because there is two schools of thought, one hot and one cold I'm going with cold as I can check easily and constantly if I just go for it I'm totally screwed if the pinion then has tight spots at the moment slow and steady seems to be working regards Stephen Forgot to add even hot you can't just crack on and get it done, it can only be done in short runs ie: the max run length is 10x the diameter of rod you are using so 3.2 mm rods equates to a max run of 32mm which has to be stress relieved by piening, every run so a lot slower than other arc welding regards Stephen Edited June 5, 2021 by Stellaghost 1 Quote Link to comment Share on other sites More sharing options...
JohnnoK Posted June 6, 2021 Share Posted June 6, 2021 Thank you. Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 6, 2021 Author Share Posted June 6, 2021 Weld, pine, wire brush reposition weld pine wire brush reposition you get the idea. Bouts of welding over the last couple of days, progress but slow Its gonna take a wee while but on the positive no cracking and pinion turns easily, not that I check it as frequently now, I think there is enough weld now that it's not going to shift position regards Stephen 1 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 6, 2021 Share Posted June 6, 2021 Good progress and patience 🙂 What’s the plan for it post welding? and once all done is everything in place to bolt it to the light weight and get some props made ? 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 6, 2021 Author Share Posted June 6, 2021 1 hour ago, Anderzander said: Good progress and patience 🙂 What’s the plan for it post welding? and once all done is everything in place to bolt it to the light weight and get some props made ? Post welding = paint and gaskets to finish back axle and then wrap it up until I'm ready to fit it. Then spend a couple of months doing the front axle. nothing ready on lightweight to receive axles as yet, but when both axles finished the bodywork will come off to start on axle fitting, all mounting points will need strengthening / upgrading for the very heavy axles. props are a wee while away yet but once ready I'll make some regards Stephen 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Stellaghost Posted June 8, 2021 Author Popular Post Share Posted June 8, 2021 Well that's the external diff welding complete Decided to dye pen it just to make sure I have no cracks No cracks but a few pin holes which I expected with the cast iron welding process. Diff stripped down and internals put into the parts washer at work Just need to remove inner circlip back grind and put a bead of weld around the inside regards Stephen 7 Quote Link to comment Share on other sites More sharing options...
CwazyWabbit Posted June 8, 2021 Share Posted June 8, 2021 Damn, you are a machine! Impressive rate of work, and nicely blended in. 1 1 Quote Link to comment Share on other sites More sharing options...
MECCANO Posted June 8, 2021 Share Posted June 8, 2021 Cant get over how well its blended in, once its painted it will almost look factor. Good effort!👍 1 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 8, 2021 Share Posted June 8, 2021 That’s outstanding ! 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Stellaghost Posted June 8, 2021 Author Popular Post Share Posted June 8, 2021 (edited) 3 hours ago, MECCANO said: Cant get over how well its blended in, once its painted it will almost look factor. Good effort!👍 Sorry, couldn't resist regards Stephen Edited June 8, 2021 by Stellaghost 5 Quote Link to comment Share on other sites More sharing options...
elbekko Posted June 8, 2021 Share Posted June 8, 2021 That's a very nice result! Fingers crossed it doesn't crack in half first trip out 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 8, 2021 Author Share Posted June 8, 2021 26 minutes ago, elbekko said: That's a very nice result!Fingers crossed it doesn't crack in half first trip out Thanks It shouldn't I've been pretty meticulous in welding it up and the dye pen results were encouraging, however I am looking at making some form of custom diff guard to protect from knocks and give additional strength regards Stephen Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 8, 2021 Author Share Posted June 8, 2021 A rough mock up of original and modified diff housings side by side pictures not great sorry regards Stephen Quote Link to comment Share on other sites More sharing options...
dangerous doug Posted June 8, 2021 Share Posted June 8, 2021 Would you be interested in potentially doing a second set? 1 Quote Link to comment Share on other sites More sharing options...
Stellaghost Posted June 8, 2021 Author Share Posted June 8, 2021 At some point in the future I don't see why not, at least I know what I'm doing now and my second diff should get done quicker once I start it regards Stephen Quote Link to comment Share on other sites More sharing options...
Popular Post Stellaghost Posted June 13, 2021 Author Popular Post Share Posted June 13, 2021 Struggling for time at the moment however I managed to finish my pinion clamp contraption Have also managed to cut extensions into two of the existing splines Going to extend all 8 as far as these ones and then see what prop shaft end fits like Very slow work my bench top mill is all manually operated also I dont have dividing head so it's interesting thank god for glasses. So far not looking too bad but that's it for today domestic duties call regards Stephen 6 Quote Link to comment Share on other sites More sharing options...
Anderzander Posted June 13, 2021 Share Posted June 13, 2021 Kit + skills + fearlessness + creativity = ⬆️ 👏🏻 3 1 Quote Link to comment Share on other sites More sharing options...
Blanco Posted June 13, 2021 Share Posted June 13, 2021 1 hour ago, Stellaghost said: manually operated Aka H.N.C. (Human Numeric Control) Looks really good under the circs 👍 1 Quote Link to comment Share on other sites More sharing options...
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