Thread: New member with a new Disco

Originally Posted by theNEWT

Wont welding the diff wear the hell out of the rear tyres? Or is this just for off roading?

It is just an off-road vehicle. But yes, you're right it will wear out the rears a bit faster. Got it welded up by a boiler maker, each of the spider gears has its corners welded. Pretty neat little job too actually. I was sceptical about the amount of weld in it, but the bloke is a damn nice welder, so it probably is equivalent to the huge amounts of slaggy home jobs I've seen and experienced in the past. I'll slot it back in tonight and look at pulling the springs.

Hey SeanP.
Post a pic of the job if you get a chance or if its not already too late.
I would like to see the quality of his welds before i weld up mine.
I intended to weld the crap out of mine. Some say weld all the way to the housing?

Originally Posted by DAMINK

Hey SeanP.
Post a pic of the job if you get a chance or if its not already too late.
I would like to see the quality of his welds before i weld up mine.
I intended to weld the crap out of mine. Some say weld all the way to the housing?

Just finishing up dinner then ill head down and take some pics. The ones I've seen in the past were as you described. Everything welded to everything. The gears welded to the housing along the top, plus a metal plate in the middle to weld it all too. I guess time will tell soon enough. If it was me welding, because I have the welding skills of about 2/10 I would need to give it a good licking.

This is a pic he sent me after he finished one side.



Seam of weld up each corner of the gears.

Originally Posted by SeanP

It is just an off-road vehicle. But yes, you're right it will wear out the rears a bit faster. Got it welded up by a boiler maker, each of the spider gears has its corners welded. Pretty neat little job too actually. I was sceptical about the amount of weld in it, but the bloke is a damn nice welder, so it probably is equivalent to the huge amounts of slaggy home jobs I've seen and experienced in the past. I'll slot it back in tonight and look at pulling the springs.

I have an off-road thing....mudder, two wheel drive, LUV Chevvy with worked Holden 202...the banjo diff was welded...but eventually both sides let go. Gonna replace it with a pajero diff.

When I used to race speedway we'd weld the spiders,and then a rectangle pate across the spiders. And one night it still came unlocked ..Gary

noticed on one pic yuo still have the rubber joint thingy at back of rear shaft. if you are welding diffs and doing all this work wouldnt this become a weak link and destroy itself? would you not get the modified shaft with uni both sides? or would it make sense to keep the rubber one so it gives before the diff? or it makes no difference?

Originally Posted by Fausto79

noticed on one pic yuo still have the rubber joint thingy at back of rear shaft. if you are welding diffs and doing all this work wouldnt this become a weak link and destroy itself? would you not get the modified shaft with uni both sides? or would it make sense to keep the rubber one so it gives before the diff? or it makes no difference?

That's a good question. I guess if find out soon enough. Maybe if that is a weak link instead of the axles it would be easier to replace. Maybe if black knight weighs in or Philip they can shed some light on it.

All in and buttoned up. And wowweee. The 80m trip down the road to the dirt car park and back, you can 100% tell it is locked. It sounds, feels and grips like it is. Car is at 193k km. Unsure on the exact number, so we can all experience how long the car holds together. On a side note, put in a falcon rotor button too. My old rotor button had a burn mark on its corner, so I assume it wasn't sending spark properly. It will be interesting to see if it makes any difference.

Originally Posted by Gary S11

When I used to race speedway we'd weld the spiders,and then a rectangle pate across the spiders. And one night it still came unlocked ..Gary

I only assume that because a speedway car is a lot more powerful and constantly gripping and spinning that the forces through the diff will be a lot higher than mine. But I am here to be proven wrong. I'll keep everyone updated on how it performs. It is fairly easy now that I know how to get the diff out, to re weld it it comes apart. Hopefully it doesn't, but if it does, no biggie.