Banjo diff straighting

H

habbott

Member
Any done this themselves. In the process of converting my diff to the Hot rod works axle modification. Needing to check diff for straightness due to welding on lugs and axle bearing ends. Starting to make up the mandrels to fit in each bell bearing location. Going to use a 1.500 inch shaft what clearance would you use to machine the shaft hole in the mandrels.
 
Made-up aluminum "donuts" on the lathe. Two for the wheel bearings and two for the carrier bearings on the inside of the "bells" This will keep everything in perfect alignment when you weld and nothing moves around. When I was done I could pull the 1-3/4 shaft out with one hand.
 
What was the shaft to hole clearance you use when you machine the mandrels? I was thinking around 5 thou clearance is this too loose?
 
Welding right around a bell is unlikely to cause problems, but welding brackets on requires equal and opposite welds to maintain straightness. The excess welds can be ground off after cooling.
 
Had a discussion last night with a toolmaker he was saying a tolerance of around .005 to .010 thou should be fine. Because of the amount of mandrels used and there position. We talk about welding the bearing ends on with this jig set up. He said to use some brass shim stock to remove most of the clearance on the end mandrel for welding.
What is your thoughts on this process?
 
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