Welded Spindles?

[vaughn4]

I need some good input from some of you experienced fabricators.

I removed 10mm from my factory steering knuckles to improve my steering angle. When i made the modification, i tapered the heck out of the parts to make for the most weld penetration. I preheated the parts with a torch and made two passes with the tig. The first pass i just went around melting the materials together. The second i used filler rod and really put the heat to it. After about 2 miles of driving i broke the drivers side knuckle right at the weld. I have another set of knuckles that i will put back on the car untill i can get these figured out.

Here are a few pictures of when i modded them. Sorry, dont have a picture of the break.

http://i53.photobucket.com/albums/g52/level7motorsports/IMG_0029-1.jpg

http://img517.imageshack.us/img517/2259/img0005yr8.jpg

http://img252.imageshack.us/img252/3041/img0006fo9.jpg

http://img263.imageshack.us/img263/1568/img0007ik3.jpg

I want some input as to how to make these hold? Please dont say send them to MA Motorsports.

[jilo]

i would say you didnt give the weld enough strength. the welder at my work is always saying the weld should be stronger than the material. id say heat em more before welding.

[onepuff]

How did you let it cool down after welding? I've heard it is good to let it cool slowly when welding cast metal. Bury it in sand after it's welded.

[vaughn4]

How did you let it cool down after welding? I've heard it is good to let it cool slowly when welding cast metal. Bury it in sand after it's welded.

I let it set in the paint booth at 90 degrees. I listened for any pinging and i didnt hear any. i think i might try to drill the center of them out and put a mild steel rod in the middle. When i weld it, hopefully the mild steel rod will melt and help. What wire did you use? Some say to use a special iron rod with the tig. ?

[onepuff]

I haven't done it myself but i've seen a few threads about modifying stock cast iron exhaust to weld on a flange for external gate and most say it needs to cool slowly.

[onepuff]

Straight from Lincoln Electric
Guidelines for Welding Cast Iron | Lincoln Electric (http://www.lincolnelectric.com/knowledge/articles/content/castironpreheat.asp)

[vaughn4]

Thanks for the help... im going to try it again, tigged with a high-nickel (like Inconel) filler rod.

[cazman]

Why dont people try to make the peices fit together like a jig saw?
Or even if you just did a diagonal cut instead of a straight cut? Then you get aprox 1.5 the weld length
Just an idea