250ex welded transfer case drive shaft
Hey there, just a pic or so of an internal drive shaft of a large suv's transfer case. It was a two piece shaft with splined interlock. Somehow the splines on one portion stripped probably after a chunk broke off off the shaft. I designed a fixture for welding the 2 halves together, as you can imagine any run out on the straightness of the shaft as a whole, in excess of a couple of thousandth's would be disasterous at RPM. The shafts were hardened steel, with a fairly nice natural bevel. Cleaned with solvent, rinsed, wire brushed and then cleaned with MEK. Root pass, and fill pass done with 308 stainless rod, to be most compatible for the hardened steel. Slow cooled at approximately 300-400 degree's per hour. Tacked in four places, and sequence welded. Finished piece had less than .002 run-out after welding.
Phew! ...... was a little concerned about that one but got lucky!
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