Need advise on how I should weld this drive shaft.

[Slednut]

My SIL turned this piece of DOM tubing down so I can make this drive shaft longer. Once I press each end on so it’s at the correct length there will be an eighth inch groove where I’ll weld it. Should I tack it at 90 then 45 degrees and then finish the welds at 90 degrees?

 

[Wrench97]

Are the ends(yokes) solid steel?
If they are you want to cut it at the welds clean it up then tap the new tube over the yoke and weld it there.
Some of that style shaft is foam filled to dampen harmonics makes them horrible to weld on.

 

[Slednut]

Are the ends(yokes) solid steel?
If they are you want to cut it at the welds clean it up then tap the new tube over the yoke and weld it there.
Some of that style shaft is foam filled to dampen harmonics makes them horrible to weld on.

Sorry, if you look close at the picture. You’ll see the DOM tubing has been turned down (shiny part) to fit inside the original driveshaft which was not filled. It is all steel. I’m pressing each end together right now to get it to the right length.

 

[welder4956]

Below is the weld sequence I use to maintain alignment on pipe and tube. Tack weld at 12 o'clock, then 6 o'clock, then 3 o'clock, then 9 o'clock degrees. The illustration shows weld pass 1 from 6 o'clock to 3 o'clock, then skip to opposite side and weld pass 2 from 12 o'clock to 9 o'clock, then weld pass 3 from 3 o'clock to 12 o'clock, then pass 4 from 9 o'clock to 6 o'clock. You could also break it into 8 segments instead of 4 and use a similar sequence. Kind of like tightening lug nuts.

 

[Slednut]

Thanks, that’s exactly what I needed.

 

[no704]

Clamp it down on some big V blocks.

 

[rattle_snake]

Clamp it down on some big V blocks.

This or use some heavy wall tubing to clamp all the piece to.

 

[zimman]

Below is the weld sequence I use to maintain alignment on pipe and tube. Tack weld at 12 o'clock, then 6 o'clock, then 3 o'clock, then 9 o'clock degrees. The illustration shows weld pass 1 from 6 o'clock to 3 o'clock, then skip to opposite side and weld pass 2 from 12 o'clock to 9 o'clock, then weld pass 3 from 3 o'clock to 12 o'clock, then pass 4 from 9 o'clock to 6 o'clock. You could also break it into 8 segments instead of 4 and use a similar sequence. Kind of like tightening lug nuts.

My watch is a digital. How's that work?
Just kidding. I had to or someone else would.
Zim

 

[vpd66]

All good suggestions. I do these all the time and have a thick walled piece of angle iron to clamp it too. I TIG weld all mine so I know I get penetration and the weld stays nice and flat and consistent to keep it balanced. Remember the weld is just holding it together and bears no structural load. The press fit is bearing the load and keeps it in line.

 

[Copymutt]

Will need to custom make a set for conversion from NP 203 to NP205 transfer cases. What are the conventional points to take length measurements please?

 

[rattle_snake]

At the u-joint caps