Ford 8.8 axle tube welding vs pinning
 

I've done some searching and there's a lot of write ups and videos on welding axle tubes but the info on axle pinning is scarce. I know most guys are just going to say weld it and get on w it but pinning seems like a good idea because I'm worried about warping the tubes. I don't really feel like building a jig just to hold my tubes either. Anyone ever pinned their tubes? And if the consenus is just to weld them, should I do it on the Jeep to prevent warping or off the Jeep.

Pinning would be better then nothing...but be very careful of drill shavings getting in the axle tube where it can get to the wheel bearings and or back into the hogshead later on.

Don't know for certain about the 8.8, but most axles are already plug welded to fix them together. The advantage of welding the seams is a massive increase in surface area for the weld.

I doubt you'd be using a pin that has a greater cross section than that of the plug weld, and as such they would be weaker. Assuming you don't have access to high tolerance machining equipment your holes would not be perfectly round to mate your pins, and then there would be some minuscule room for deflection and that portion of the tube that was drilled for the pin will become significantly weaker.

Just my two cents, not sure if that is very accurate of the reality of the situation, but something to consider.

Casting such as the pumpkin need special welding procedures. The interweb have many tutorials on this. Preheating of the casting is oft the prerequisite to welding the casting. Cool down is also important.

Does the entire circumference need welding or perhaps just weld in a few spots? Id not think you need full circumference welding, maybe that will be easier?
I see one spot where it appears you got good weld penetration, the rest, not so good.

Maybe I have been living under a rock, but I haven't heard of the tubes spinning or backing out. They are pressed in with at least 30 tons and then plug welded which would take out the entire casting if you did loose one. Unless somebody says something different, I say they were OK to start with

It happens. IDK about the 8.8; it's probably built better. But I have rotated a pumpkin on an old AMC 20. Makes for a terribly shaky ride home.

First I have heard of the 20 doing that. As far as the more modern axles to do that is the D44A with the aluminum housing. No plug welds on that one

I have seen a Ford 10.5" do that.

It's really common:

https://www.jeepforum.com/threads/is...otate.3012145/

Admittedly my experience with them goes way back before rock crawling was popular

I doubt many tubes spin.
one in 500k of jeeps does then Internet is ohhh my god your Auto lockers spun the tube.