Front Axle RovingTracks Toyota Conversion - Defender Source
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  #1  
Old December 3rd, 2012, 10:42 PM
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Front Axle RovingTracks Toyota Conversion

Starting a thread to document my front axle project. Like all things I do, it has been slow going. I think I dropped the axle housing off to get sandblasted back in September. Btw, thanks to bossman/Adrian for the axle housing!

Here is the small list of things that are done so far:
- axle sandblasted
- old diff studs popped out and filled
- new diff studs welded in
- diff interface cleaned and sanded down
- stock cap grinded off and sewer cap has first pass of weld
- all replacment parts ordered and on the shelf including Keith's trick Toy conversion - thanks to RovahFarm for the parts.

Attached are the pics so far

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Hoping to get the 2nd pass done tomorrow. My TIG skills still need a lot of work but starting to get the hang of it. I am hoping it doesn't leak too bad the first time trying it.

Let me know what you guys think - thanks!
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  #2  
Old December 3rd, 2012, 11:05 PM
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Quote:
Originally Posted by JSBriggs View Post
Did you prep that pipe cap, it looks a bit tall. Or are you dunning one of Keiths bent panhard rods?

-Jeff
It was machined by Keith - it is a bit tall but figured that was due to keeping things from hitting. I do have the RovingTracks panhard rods already.
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  #3  
Old December 3rd, 2012, 11:22 PM
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Nice weld! It looks autogenous.
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  #4  
Old December 4th, 2012, 07:14 AM
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The letter m is missing from your table alphabet.
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  #5  
Old December 4th, 2012, 07:43 AM
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you may triple bead it. for more strength, and extra insurance
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  #6  
Old December 4th, 2012, 08:48 AM
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Looks great don. I'll have to swing by to check it out. Glad you could use the housing!
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  #7  
Old December 5th, 2012, 06:58 PM
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2nd pass - a little messy in spots but think I got good penetration.

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Shelf of goodies. Placed an order to POR-15 yesterday. Hopefully get it painted/coated next week. Then I can pick away at putting it together.

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It's on the garage floor now with water in it for a leak test. Looked pretty good but will check it later. And I would think the POR-15 should close up anything little.
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  #8  
Old December 5th, 2012, 07:05 PM
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Quote:
Originally Posted by sonoronos View Post
Nice weld! It looks autogenous.
Thanks - still a lot to learn but it is a good exercise. One thing about having a TIG box and a Rover - easy to find projects for each other, haha. After the axle is done I need to mod the passenger bracket and I want to make my own storage lockers and then reinforce the sliders, and...

------ Follow up post added December 5th, 2012 07:08 PM ------

Quote:
Originally Posted by JSBriggs View Post

Yes, very nice. How long have you had the TIG? Im jealous.

-Jeff
I got it last winter but it took me a few months to get it wired and setup. Found a ratty welding table on Craigslist for cheap and it looks like shit but it tough. Made a little section in the garage just for welding.

Its nice having a tig box - lots to it but the more I learn the more I like it.

------ Follow up post added December 5th, 2012 07:11 PM ------

Quote:
Originally Posted by rijosho View Post
The letter m is missing from your table alphabet.
Haha, youngest (6 at the time) went to town with the silver Sharpee (I love those pens). Makes me laugh when I see them scattered on different things (they know to ask before they tag up things).
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  #9  
Old December 5th, 2012, 07:16 PM
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Quote:
Originally Posted by killahaas View Post
you may triple bead it. for more strength, and extra insurance
My buddy said 2 passes with TIG should be fine. He is a pro welder. I will check with him again and show him the pics. I am worried I might flub it up going one more time around. Will check with Keith too and show him the 2nd pass pics.

------ Follow up post added December 5th, 2012 07:18 PM ------

Quote:
Originally Posted by bossman429 View Post
Looks great don. I'll have to swing by to check it out. Glad you could use the housing!
Thanks Adrian - it would probably be overkill but could be cool to have a fabrication/weld section on here. I know you have been busy melting metal too.
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  #10  
Old December 5th, 2012, 07:29 PM
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Thanks Adrian - it would probably be overkill but could be cool to have a fabrication/weld section on here. I know you have been busy melting metal too.[/QUOTE]

YES we do need a fab/weld section. but can i ask what kind of welder do you have? did you preheat the cap at all? because that is like 1/2inch right?
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  #11  
Old December 5th, 2012, 08:29 PM
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Quote:
YES we do need a fab/weld section. but can i ask what kind of welder do you have? did you preheat the cap at all? because that is like 1/2inch right?
I bought a Lincoln Precision 185 from my buddy. I was a good deal and is fine for my skill set.

I didn't preheat the cap. The axle housing is thick too where the cap meets. And Keith machines a bevel on the cap too. I will measure next time I am out in the garage. I was more worried about getting penetration into the housing more than the cap.

For technique on this 2nd pass I turned it all the way up to 185 and eased the pedal down until the prior bead starting to make a puddle then went all the way down and kept the torch in the middle/a slight bit towards the axle housing. Dipped the wire onto the top of the puddle so it would flow down/fill in. Or at least that's what I was trying, haha. Easier said then done.

Also, I have to double check but my post flow gas was turned up all the way up and running 20cmh. Not sure what size cup but 3/32" tungsten. Want to get a shorter cap for getting in certain places.

Like I said, would love to have a section to talk turkey about metal prep, settings ,etc.
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  #12  
Old December 5th, 2012, 08:35 PM
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yes, 3/32 tungsten isnt the best for thick metal. also i am not sure how much of a bevel it was. but preheat is always nice. also if you dont feel confident with just the two welds, try a double bead weld. (heat top, dip, heat bottom, dip, more forward, repeat) but the lincoln 185's are sweet i like them.
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  #13  
Old December 5th, 2012, 10:01 PM
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Quote:
Originally Posted by don View Post

Like I said, would love to have a section to talk turkey about metal prep, settings ,etc.
Best place to do that is over on OFN.... some pro-welders on there that help beginners out lots... linky http://www.offroadfabnet.com/forums/index.php
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  #14  
Old December 6th, 2012, 12:59 AM
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Don the welds look great. You like the tig so far? I used my hobart 210mvp mig cranked up pretty high cause I too (being fairly new to welding) was worried about penetration..
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  #15  
Old December 6th, 2012, 07:57 AM
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Quote:
Originally Posted by killahaas View Post
yes, 3/32 tungsten isnt the best for thick metal. also i am not sure how much of a bevel it was. but preheat is always nice. also if you dont feel confident with just the two welds, try a double bead weld. (heat top, dip, heat bottom, dip, more forward, repeat) but the lincoln 185's are sweet i like them.
Thanks - I know I need to get more supplies to fit each job better. I was online looking at different torches and will hit up the local dealer soon.

At one point I was doing what you were saying but the bead looked weird when I was done. Maybe not enough filler and/or moving to quickly. I will read more on multipass tig beads. I like how the beads look now and it seems sealed (no water leaks last night) but want to make sure it is on strong enough.

But thanks for the help and tips - I am sure I will be asking some more help on future projects.

------ Follow up post added December 6th, 2012 07:58 AM ------

Quote:
Originally Posted by Landy_Andy View Post

Best place to do that is over on OFN.... some pro-welders on there that help beginners out lots... linky http://www.offroadfabnet.com/forums/index.php
Thanks - will add that to my daily check out list.

------ Follow up post added December 6th, 2012 08:01 AM ------

Quote:
Originally Posted by Jake1996d1 View Post
Don the welds look great. You like the tig so far? I used my hobart 210mvp mig cranked up pretty high cause I too (being fairly new to welding) was worried about penetration..
Thanks Jake - I like the Tig but to be honest it is all I know. Bossman/Adrian has a mig box that I might check out one of these days. At some point I want to be able to make bicycle frames but that is sometime down the road. But the Rover projects have given me time to learn a bunch.
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  #16  
Old December 11th, 2012, 07:03 PM
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Got 2 coats of POR-15 on the axle yesterday and last night.

Need to call them and see when I can primer and spray a few coats of Chassis Black. There is not really any good info about it on their website.

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  #17  
Old December 11th, 2012, 07:28 PM
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Wow! Looking good man. can't wait to see the finished job.
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  #18  
Old December 11th, 2012, 10:20 PM
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Quote:
Originally Posted by JSBriggs View Post
Judging by the misc in the background, looks like your lacing up a new wheel too!

Looks good.

-Jeff
Haha, those are old spokes that I have been hoarding for the last few years. I was going to ask my welding buddy if I could use them for filler as I am just about to toss them but hate tossing things I think could have a use.

I do need to build a new set of wheels. I am running 36o wheels with Hope hubs on my dj rig and want to swap over to Profile hubs especially the front. Since I only run rear disc I am going to use the trick looking and more importantly centered flanged Profile non-disc 20mm. Last Friday at Cranx the front wheel was feeling flexy on some of the hip jumps. I don't like running wheels dished if I don't have to. Thought it would be fine and the Hopes were a great price.

------ Follow up post added December 11th, 2012 10:21 PM ------

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Originally Posted by Neil McCauley View Post
Wow! Looking good man. can't wait to see the finished job.
Thanks Neil! Going to be forever until its under the truck. I am slow as shit.
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  #19  
Old December 16th, 2012, 05:40 PM
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2 coats of POR-15 - dried for 3 days, then Etching Primer and a can of Chassis Coat Black. Will start plugging away at putting it together next week.
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  #20  
Old December 16th, 2012, 06:03 PM
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Looking good Don!
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