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sals shave problem.

Tech Talk for Rover owners.

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sals shave problem.

Post by F'n_Rover »

is there any trick to welding the sals housing?
last night i cut out the filler and welded in a plate to fill the hole.
when i ground flat and polished the welds - fark me, some nice crack lines showed up along the welded area :x (along the welds )
I'll be v- grinding the cracks and rewelding, but want to know if I'm missing something ? the housing is just mild steel, isn't it?

i belted the bejesus out of the filled area and it didn't pop out :?
but i dont like cracks. any thoughts.

thanks
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Post by RUFF »

I beleive the housing is Cast not mild steel. Are you Pre-Heating the housing before you weld it?
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Post by F'n_Rover »

no i didn't pre heat :roll: . Thought welding cast steel was like normal mild steel. looks like i'll have to cut it out and start again.

How hot do i have to pre-heat? glowing?

thanks.
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Post by ISUZUROVER »

popeye wrote:no i didn't pre heat :roll: . Thought welding cast steel was like normal mild steel. looks like i'll have to cut it out and start again.

How hot do i have to pre-heat? glowing?

thanks.
No, just a dark straw colour - have search on pirate for welding cast steel/iron and shaving a d60. Plenty of info.

Edit - you also want to cool it down slowly.

When I shaved mine, I just welded the drain plug in place from the inside then shaved it.

EDIT No.2 Popeye, while you have your Sals out, could you do me a huge favour and measure:

Length of each axle and length of splined area.
Inner and outer diameter of the carrier bearings.
Width of the centre (side gear-side gear).
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Post by F'n_Rover »

thanks, will get over to pirate.
in hindsight i should've just ground the lump off rather than cutting it out, but hell thats a lot of metal to grind away. :shock:

below measured with a fold out chippies rule - hope they are of some worth.
long shaft = 830mm (from c clip grove)
short shaft = 647mm (from c clip grove)
outer spline long maxi = 30mm (from inner face of c clip grove)
inner spline long maxi = 40mm but 35mm used (worn)
outer spline short stock = 35mm(from grove)
inner spline stock = 45mm / 33mm used
carrier width = 220mm(measured from housing face not from centre)
(measured with a steel rule)

centre bearings = outer cone = 382-s inner race = 387a specs will be somewhere on the net.

spline lengths are the usable length not total

is this needed for the front sals project ?
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Post by ISUZUROVER »

Thanka a lot popeye, that is what I was after. If you can though, one last measurement would be great - how far inside the edge of the carrier does each side gear start. i.e. you measured 220mm across the housing where the centre sits, but the measurement from side gear-side gear must be a bit less.

You are right it is for the front Salisbury. Also seeing if it is possible to make a 35 spline salisbury locker (of similar design to MD).

EDIT - by cutting a chunk out and welding flat plate in, you can end up with more shaved off. And some of the US guys machine the ring gear down to get even more...
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Post by F'n_Rover »

not quite sure if this is what you mean - but from outer most face of edge gear to the part the carrier bearings sit is 49mm. give or take a bit.
from the actual back face of the gear is 60mm.


[[[ 60mm | < outer most part of carrier
[[[[[[[
[[[[[[[ 49 |
[[[[[[[
[[[ <side gear
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Post by ISUZUROVER »

This might make things clearer - are these dimensions right? What I really want to know, is how wide is the diff centre from side gear outer edge-side gear outer edge (A). You have measured (B) - outside of carrier bearing - outside of carrier bearing, and if you subtract 2x(C) from this measurement you get (A). So is 49mm right for (C).
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Post by F'n_Rover »

your picture sux :D but yeah its right. the ??? measurement i cant realy measure atm without pulling the centre apart. I'll get a vernier tomorrow and measure proper.
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Post by TLCOR »

How much clearance are you guys gaining by shaving your diffs ?
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Post by ISUZUROVER »

popeye wrote:your picture sux :D but yeah its right. the ??? measurement i cant realy measure atm without pulling the centre apart. I'll get a vernier tomorrow and measure proper.
You want a better picture??? Here you go...

Thanks for taking all the measurements.


TCLOR - I gained about 15mm. You can shave a LOT more off though.
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Post by F'n_Rover »

115mm between outer most part of side gears. give or take.

TCLOR -I gained about 20mm in clearance, but the main thing is a smooth bottom. smooth, just like a perky young woman's rear. a beautiful thing.
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Post by "CANADA" »

anyone been keen enough to mohawk-shave there sal? or any rover diff for that matter.
[quote="dazza30875"]whats "FAIL" mean[/quote]

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Post by ISUZUROVER »

popeye wrote:115mm between outer most part of side gears. give or take.

TCLOR -I gained about 20mm in clearance, but the main thing is a smooth bottom. smooth, just like a perky young woman's rear. a beautiful thing.
Thanks a lot popeye, much appreciated. I owe you a beer some time.

mad landie - never seen one in OZ, it is a LOT of work and because of the reduced oil capacity I would only do it to either a front diff or an off-road only truck.

EDIT - oh and a little bit of clearance makes a huge difference. I was once at Big-Boys 4x4 park (now closed) with the Brisbane LR Club. There was one hill that vehicles with rover diffs and 32" or larger tyres could drive straight up. I (also on 32" tyres back then) grounded out on the salisbury (even though it was shaved), and then a mate in a 110 county on 33's with twin lockers tried it - he grounded on his unshaved salisbury. I then put his 33's on my IIA, and walked straight up the hill with no lockers, just like the rover diffed guys with 32's were doing.
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Post by F'n_Rover »

Update -
i got some CIG weldall arc rods. These did the trick, no preheating. The original welds i used a gasless mig and stitched it up in little passes letting it cool between, (to avoid warping :roll: ). The weldall rods wern't cheap - $25.00 for 15 of them, but they welded beautifully.

The housing is about 5mm lower than the stage 1 front diff, but would be higher than a standard series housing, due to the drain plug.

all happy now.
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Post by Tdi200 »

Any pics please??

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Post by F'n_Rover »

finally got the camera out :roll:
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Post by F'n_Rover »

some more -

There is around 4mm clearance between the crown wheel and the housing. Hope its enough.
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Post by ISUZUROVER »

Looking good, what thickness is the plate you welded in???

If you want to get really serious, some guys in the US have put the ring-gear in a lathe and ground it down square.
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