I have installed a sway bar on my 78 CJ5. I have replaced the lower spring plates with the ones that have two posts pointing towards the tire, one on each side of front axle. The rear post is for the shock and the front would be for the disconnect. The disconnects will not disconnect due to clearance problems. The JKS disconnects came with a tab that can be welded to the axle tube to act as the lower connection point for the disconnects. My question is simple. I do not want to remove the axles from the tube. I just want to weld the tabs. Is there a trick to not boiling out all the axle grease or is that not really an issue? I have ran searches on the topic but the search tool takes "Weld", "Axle" and "Tube". As you can guess, there are over 250 threads that have those words and although there are some really nice build threads, I am not finding the answer. Thanks for all the help in advance.
Having a 4x4 shop do the welding would be best. You can wrap the axle tube either side of the weld in wet towels to absorb the heat. Weld short beads, with plenty of time between welding sessions to keep the heat build-up to minimum.
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Welding a tab your not going to build heat in the tube like you would on something larger. Skip around from side to side with some short pauses in between and you will be OK. Just make sure the metal is clean and get some good penetration. What welder/wire/gas are you going to be using?
Beat it to fit, paint it to match!