SAS project diff armor question

[Dedtruk]

I want to weld diff armor onto my mini axles (SAS project). I'm concerned I'll crystallize the metal or cause other damage to ring and pinion, bearings, seals, etc, if I weld the armor onto an otherwise complete axle. Of course, I'll drain the gear oil out first and weld in short (1 inch or less beads, but ... ). I've used the search function and haven't found an answer. Thoughts? Thanks for your input!

 

[KLF]

I made mine (F&R) out of 8" pipe caps, but I did all my welding with the housings out of the truck, empty.

I believe many have installed them with the axle in place with no issues. Here's some instructions from the Low Range website, showing how to do a rear axle:

http://www.lowrangeoffroad.com/down...ial-Guard-for-Hilux-Pickup_4Runner-Tacoma.pdf

 

[Dedtruk]

KLF, thanks! I have aftermarket diff armor already but I appreciate the pipe cap suggestion. They work well too. I was just saving myself the fab/chasing around time. BTW, Barnes 4WD makes a replacement cap that I think beats all for aesthetics and beef ... in case you ever decide to build another axle. I hear your resto is coming along nicely. GL with it, and thanks again!