I've got a 135amp mig welder with a good power source. I'm going to need to weld some 3/16" steel to my axle tubes. My question is do you think this welder will do this well? I have never tried to weld on anything so thick. Obviously it can handle the 3/16", but will it get enough penetraition on the axle tubes to make a strong weld? Anyone know how thick axle tubes generally are on a 12 bolt? I know it can handle up to 1/4" steel pretty well.

 

The axle tubes are 3/16" or 1/4". A 135 amp welder should make a solid 3/16" weld no problem.

 

For some reason I thought they were thicker. Good to hear. Thanks.

 

I wouldnt weld on the tubes. To keep the axle housing from bowing you need the housing in a jig. I normally cut the ends off and set the housing in a jig and do all my welding then weld the ends back on.

 

I am welding on the mounts for a rear sway bar. I didn't think most people removed the differential for this. Here's a pic of it. You can see it in the upper right corner. I don't have a jig or anything tp put it in. Any good alternatives to do this with the rearend in the car?

 

I think welding those on is overkill, but it does look clean. Most people just clamp them on with 3" exhaust clamps. There's practically no load on them. I think if you use a couple small welds and let the housing cool inbetween, then you shouldn't risk warping the housing. Maybe just lay a 1" bead on each end of each side of the brackets and call it good. I'd use a damp rag to cool the welds after each pass.

Craig