Welding up a Sami diff

[MTBLAZER89]

Anybody ever done it? It has to be done inside the carrier. I think I have a pretty good plan of action by welding the bottom side gear and two spiders through two windows in the bottom then rotating the assembly 90* to get the other two spiders through the windows. Then installing the cross pins and working my way around them and the spiders finally installing the top side gear and filling the remaining voids. Here are a few pics of the carrier in order of assembly.

 

[MTBLAZER89]

Ok any tips on preventing the amount of spatter sticking inside the splines on the side gears? I'm still using flux core

 

[blazinzuk]

anti spatter spray.

One thing make sure when you are welding on the top side of it that you dont' get any weld higher than the mounting surface. I have done a couple like you said and one of them somehow I messed up and could not get the outer plate on it. Also I have warped a carrier enough to make the holes not line up.

That was on a bet though

 

[brian wafer]

a friend off mine had welded only in between the teeth off the satilite gears,you could fill up the gear tooth on a bench and assemble after.the rear end was not welded solid.it worked ok for the couple off years he had it,was on front end!