[George Zinger]

This might be a foolish question but I just want to make sure it won’t create a problem. Weather is cooling and I hope to get into replacing my brake lines. Brakes are fine just not a neat installation. In preparation for the project I would like to spot weld a couple bendable tabs to my rear axle housings to secure the new lines. Any advice or precautions of what to do or not to do would be appreciated. Thanks in advance.
George

If I posted this in the wrong place please feel free to move it to where it belongs.


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[copymutt]

I relocated my rear brake run to the drivers side & welded new tabs to the axle. Pretty straight forward. I did disconnect the battery and alternator as I have a trunk mount battery.

 

[George Zinger]

Looking for some welding advice. Back in the day I was a half assed welder with a Lincoln stick welder. Today I struggle with a 110v flux core unit which so far has served my needs OK. I fabricated the brake line tabs, made extras for mistakes and am now trying to figure out if there is a neat trick to holding them in place while I do the spot weld? I know I have to clean up to bare metal where they are going but I know I will be challenged laying on my side (no lift) trying to hold it in place and accurately hit the hole I want to spot weld thru. Will wrapping around the axle with wire hold them tight enough or do I have to figure out how to clamp? Appreciate any help!
George

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[George Zinger]

Today I tried welding a couple extra brake line tabs to a piece of 1/8” stock, tabs are 16 gauge. I am humbled as it was disastrous, welder speed on 4 set for thin plate. First it burned up the 16 gauge pretty good, I had it on thin plate to get penetration. I was holding the tab with vise grips and don’t know if I was putting enough pressure down force. And of course I couldn’t hit the hole in the tab I thought would make a neat spot weld! Second attempt wasn’t much better but ended up building weld around the tab and probably made it brittle. And this was working on my welding table under good conditions. No way am I going to pull this off laying down under the truck….
Plan B, drill and tap threads for a SS #10 screw with Loctite. Probably file a shallow flat spot for the tab to sit on. I figure with a vacuum and magnet I can control the fillings. I am wondering how thick the steel is on the rear axle tubes, it is a 9” Ford housing. Any help or advice would be great.
George


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