Heres what you do.

Further investigation of my ring gear. I figured out what happened. I also talk to howie.

Dp not weld your spiders. They are the weakest part of the gears. Howie said the teeth gave at the weld and it spit that piece out and it went to the bottom causing it to get caught up in the ring gear,scratching my housing and taking the chunk out of my housing.
He said I went about welding it the wrong way

Howies says you need to weld the side gear to the sub assembly on both sides, He said you need about 1/2 to 1 inch weld on it. To do away with the cluches and couple it all to gether. Basically making it a straight axel front end. He said this will allow it not to move and not having a chance to chip off when it comes in contact with the spiders. He said LEAVE THE SPIDERS ALONE!!!!!

Trail and error makes you better!! He said there is no way under any driving condition this should happen. other than the spiders being forced to move and not holding up to the locked position the teeth gave way!! MAKE SURE YOU WELD THE SIDE GEAR TO THE HOUSING!!!

I willkeep you posted on round 3 soon

 

I welded my other sub assembly today and i ordered 2nd day arrival on my new outer assembly so it will be here Wed. I can put it all together then.

I welded the side gears to the Sub Assembly. This makes sense because yo uare basically taking away the abillilty for the clutches to work not allowing it to slip. This is exactly what howie does when he buts open the welded ends of the sub assembly. He takes the clutches out of the ends and puts a still ring that wedges the side gears and keeps them from moving.

Also this is exactly what my father in laws did to his bike. Witch was remove the ability allowing the clutches not to slip. It becomes a solid axel sorta speak.
This is were the problems come in to do with the CVs.

 

CatKrazy- So your saying a piece of your weld broke off , fell to the bottom of the housing and broke the case? I welded the upper spider gear to the assembly as well as the gears together to themselves. Is this what you did ?

 

no i just welded 4 spots on the spiders themselves! BIG MISTAKE

No the weld di not give, It was the teeth on the spiders that gave!!

Yes weld the side gears to the housing that way when the pinion turns the ring gear, the ring gear turns the two front shafts. The ring and pinion if you noticed are made of a lot bigger steel and alot thicker

 

In other words i left the side gears were they would turn and bump up to the spiders and then lock which was about 1/32 on an inch before they would hit the weld on the spider. The welded teeth on the spiders gave causeing the teeth to get caught in between the teeth of the ring gear,which caused the scape in the housing,it then kept turning until the ring gear turned the piece into the plug screw causing it to sheer off.


You will be ok I believe. Your Cvs will go before your Diff will. You did yours right! I did not!!!

 

ok on the explode view at brown leisure world what nubers needs to be welded together. i see where number 37 is the spider gears. where is the clutches.

 

Max- The spider gears and clutches are inside of # 37. You can't see them in the diagram.

 

You cant get to the clutches! but do oyu see where the opening is for the spindles to go in. right there is where you clutches are. and on the backside of the clutches is where your side gear are. You need to weld you side gears to the housing and to hthe spiders. Make it one whole piece were you #37 is turning both front axels and you will be fine!!

 

thanks i think i got what you are saying