Welding Dana60 casting?
Thread Starter
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Senior User
Joined: Mar 2007
Posts: 204
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From: Qld Australia
Welding Dana60 casting?
Has anyone successfully welded any reinforcing etc. on to the casting (third member?) of a dana 60 (or other dana's)?
I'm considering fully bracing the whole thing as part of a project build that will require all new suspension mounts as well.
Would love to hear from anyone that has. Thanks.
I'm considering fully bracing the whole thing as part of a project build that will require all new suspension mounts as well.
Would love to hear from anyone that has. Thanks.
Post Fiend
Joined: Oct 2003
Posts: 5,903
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From: MICHIGAN
1st you need to know the type of material you are welding ie. cast iron, cast steel. I don't know.
If it's cast iron you will need special welding techniques beyond the scope of most of us. Ususally requires an oven to heat everything before welding and then back into the oven cooling the metal down slowly. Pretty big oven huh? Then you have warping so it will need to be straightened.
Cast steel can be tricky but do-able. A really big torch comes in handy for pre-heating b4 welding. Same warping problem though. Bracing the rear diff will help keep the warpage to a minimum.
I have built a couple narrowed rear diffs (ford 9") but not welded on the casted parts just for the reasons stated above. I have a big steel table that I used for fixturing the housing and axle tubes that kept it nice and straight.
If it's cast iron you will need special welding techniques beyond the scope of most of us. Ususally requires an oven to heat everything before welding and then back into the oven cooling the metal down slowly. Pretty big oven huh? Then you have warping so it will need to be straightened.
Cast steel can be tricky but do-able. A really big torch comes in handy for pre-heating b4 welding. Same warping problem though. Bracing the rear diff will help keep the warpage to a minimum.
I have built a couple narrowed rear diffs (ford 9") but not welded on the casted parts just for the reasons stated above. I have a big steel table that I used for fixturing the housing and axle tubes that kept it nice and straight.
Thread Starter
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Senior User
Joined: Mar 2007
Posts: 204
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From: Qld Australia
Thanks Jim.
I've done a 9" before, the bracing I put on it was all very symetrical so there was virtually no warping. But the housing on them is all fabricated/pressed sheet steel and tube. Whereas the dana's have the cast middle section (and ends on a front axle).
I have some really heavy universal column steel that I can make a strong-back with, and if I keep the bracing symetrical again, and preheat, I think I should be ok. Dana's would have to be cast steel to be strong and tough enough, and the tubes are pressed and welded in. Pressing into cast iron would probably crack it.
Anyone else had any experience or able to correct me if I'm wrong?
I've done a 9" before, the bracing I put on it was all very symetrical so there was virtually no warping. But the housing on them is all fabricated/pressed sheet steel and tube. Whereas the dana's have the cast middle section (and ends on a front axle).
I have some really heavy universal column steel that I can make a strong-back with, and if I keep the bracing symetrical again, and preheat, I think I should be ok. Dana's would have to be cast steel to be strong and tough enough, and the tubes are pressed and welded in. Pressing into cast iron would probably crack it.
Anyone else had any experience or able to correct me if I'm wrong?
