Fabricate and Weld New Axle Tubes
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WE ARE BACK! one ton build!
What happens here
With the old axle tubes removed, the differential housing must be thoroughly cleaned and prepared. Any burrs, sharp edges, or remnants of the old welds should be ground smooth to ensure a clean mating surface. New steel tubing, often chosen for its increased strength or specific dimensions (such as square profile tubing), is then cut to the exact desired length for the custom axle width. These new axle tubes are then meticulously fitted and aligned to the prepared differential housing. Once positioned correctly, they are welded into place using a suitable welding process. The welding must create strong, continuous beads to ensure the structural integrity of the axle and maintain proper alignment, which is critical for vehicle handling and safety. The video briefly shows the new tubes being mocked up and then the subsequent welding, indicated by sparks and the finished weld bead.
Goal: Attach new axle tubes to the differential housing
Tools and materials
- Angle Grinder — Cleaning up the differential housing, shaping the new tubing for a better fit, and smoothing finished welds
- Differential Housing — The central component ready to receive the new axle tubes
- Measuring Tape — Accurately measuring the lengths for the new axle tubes and ensuring overall axle width
- New Steel Tubing — The material for creating the custom-length and potentially stronger axle tubes. Appears to be square steel tubing
- Welder — Fusing the new axle tubes to the differential housing
- Welding Gloves — Protecting hands from extreme heat, sparks, and sharp metal edges during welding and metal handling
- Welding Helmet — Essential for protecting eyes and face from intense UV/IR radiation, sparks, and spatter during welding
- Welding Rods / Wire — The filler material consumed during the welding process to join the metal components