TIG welding axle flanges??

[80's_delirious]

Is it possible to TIG up bolt and dowel holes in axle flanges to re-machine them at different PCD with out compromising the strength of the axle and flange?

I have fitted 80 series locked diff centres into 105 series housings, this meant I had to use 80 series axles (different splines) The PCD for hub bolts and dowels is slightly different. I had a crack at re-drilling holes to the new PCD but I have two leaking axle seals after only 8weeks, so it appears I haven't quite got it right. I am thinking of having the current holes TIGged up, re-machine the flanges and re-drill the holes for hub bolts and dowels.

Am I asking for trouble? (in terms of strength, failure, embrittlement etc?

What problems could occur?

I am looking for the tight arse option here. I have other options, but they are all going to cost more than I want to spend at the moment.

[dck7aok]

Tight arse option: Just Do it.
The Toyota stuff is usually pretty good. Still nees preheating and someone with some skills on the torch.
Take the oportunity to upspec the studs/bolts.
You have sacrifised some strength with the 80's stuff anyway.

[80's_delirious]

Yeah, I have already gone to longer socket head cap screws instead of studs.

If I have a failure, I can revert back to all 105series stuff if necessary. But would lose my rear locker to do so.


Any suggestions of someone in Shitney who can do this for me?

[Z()LTAN]

Ive miged up my axle flanges when the studs and dowels broke the hub open elongating the holes in the axle. Has held up fine so far.

[80's_delirious]

Cheers Zoltan, good to know.