Outer Limits 4x4 Board

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.

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.

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?

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.

Cheers Zoltan, good to know.