Tig welding with nickel 99

[wils1514]

Tarry,
thanks for the info! Already had the 8.8 from a previous project. Replaced the axle tubes with 1/4" wall.
That rear looks stout! Mine is going in a 1967 mustang so nothing too crazy and it won't be taking too much abuse....

[wils1514]

Rear end is a Ford Explorer 8.8. Maybe from an early 90’s with drum brakes. 3 1/41020 dom steel tubing. I’m putting 9” bearing ends on and have the alignment bar and bushings. Pretty typical stuff for an 8.8....

[wils1514]

Ryan- thanks for the info. If it's cast steel will it produce some filings?

[wils1514]

Here is the practice part with the crack...

[wils1514]

I have done quite a bit of research on it. Some say the housing is cast iron while some say cast steel. I feel like my mig welder doesn't have the capability to weld the tubes and housing.
it seems like the proper procedure is to preheat, weld using nickel filler, and post heat.

[wils1514]

The project is welding a rear end center housing to mild steel axle tubes.
The practice pieces were some 3.5 od tube pressed onto a 3.25 od tube. Both mild steel. I used DCEN at 160 amps....

[wils1514]

So I am getting ready to weld some cast iron or cast steel to some mild steel. I have nickel 99 rod that I knocked off and cleaned all of the flux off of. I was practicing on welding some mild steel tube together today using the nickel rod and when I was done it had a crack through the whole weld. I...

[wils1514]

Yes the tubes were pressed in. I ended up cutting the tubes down where they meet the center housing and cut the rest of the tube that was still in the housing in half so I could pull them out. Its an explorer 8.8 so they are 3.25" tubes that will be turned down. The bore where it goes into the...

[wils1514]

I have a ford 8.8 center section with the axle tubes removed. I have drilled out the 3 plug welds per side and removed the tubes to install longer ones. I have heard that the 8.8 is cast steel but people also say it is cast iron.
My question is what is the correct way to weld the plug welds. Mig...