I have refined my process over the years and used this method for the last 5 or 6 axles.
I remove the carrier from the axle, mark the ring gear location and remove the ring gear. I use a threaded rod fixture to hold the side gears in place and a couple of sleeves I made up to centre the side gears in their holes in the carrier.
Then I cover the seams where the edges of the side gears meet the carrier with masking tape and spray the whole thing with anti-spatter solution. This prevents weld spatter and "BB's" from collecting where I don't want them to.
I use a MIG welder with CO2 and solid .035 wire to weld the side gears to the carrier where the tape had been. Use lots of wire and voltage to get good penetration and weld the four locations in a crisscross pattern, letting it cool somewhat between beads.
After it has all cooled naturally, blow all the little balls of spatter out of the assembly, wash the carrier thoroughly in the parts washer and blow it all dry again. Reassemble the ring gear and put the carrier back in place. You won't be able to get the small pinion gears in, but it doesn't matter because you just made the carrier into a spool. The cross pin will easily come in and out to facilitate axle removal/installation in the future.
Oval racing helps you unwind because you race counter clockwise.
2007 and 2008 Ohsweken Speedway MiniStock Champion
2007 and 2008 Merrittville Speedway 4 Cylinder Champion
2009 Humberstone Speedway MiniStock All Canadian Champion
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