I want to weld up my spare rear third and would like some input from people that have done it. I have a 91 Tracker. I would like to know whether you filled in the side gears or the spiders? Did you leave any play in there for a semi fozzy effect? Does anyone have pics of it or a good link that gives details?
Thanks in advance
Cheers

 A friend of mine did that a couple of times, his best results were welding it solid. He added about 3 pounds of weld in the carrier!
Personally, I'd spend the hundred bucks and get a spool from Brent.

Personally, I'd spend the hundred bucks and get a spool from Brent.

Will Brent's spool work in a Track/Kick, or is that just for Sammi's?

EDIT:  Yup, it will!

http://www.trailtough.com/lockers.htm

I weld mine in the Sammy Hybrid rear, soon to swap the welded third into the Kick.  

I've had the best sucess with welding it soild, don't try to just weld the gears together try to fill every empty space with molten metal.  And if it breaks, as long as the pieces have no where to go it will stay locked.  My first welded sammy rear lasted 5 years and 3 owners before it trashed the pinion bearing.    

When you are done it should look like the gears were placed in molten metal and just the outer teeth are exposed to enguage the side gear.  Clean it well / remove all the gear oil,  I use lots of brake cleaner solvent.   Use a welder that will produce plenty of heat.
Usually we get them hot enough to change the bearinge to a blue purple color,  I'm sure the heat and distortion are terriable but they live anyway...

In theory the bearings and ring / pinion will not like the slag, splatter, or heat.   But if it is a spare go for it.  I've had great sucess with these and if you have a spare 3rd and a welder it's free...

I've taken a pic before but it didn't turn out good.

I was always told that if you are going to weld up a rear end you should weld up the teeth.

And what I mean is you build up the teeth.  Make them taller so that they will interfer with each other and "lock" up.  Try to be sure that both sides engage at the same time.  That way one set of gears aren't getting all the preaser.

It's been a while sence I've look at a third member, but weld up the part that you can remove the easist after they are welded.  That way if something brakes you can replace it.

Also, you don't have to worry about the heat getting to the other parts like mentioned above.

i have had mine locked for a year.  works great.  but if i would have known Brent was selling mini spools then i would have just bought one.  welding just sounds cheap.

stu

Thanks for your tips guys, I started filling in the spare teeth today and am taking my time to ensure that I get it as even as possible. I'll try to get a couple of pics as I get it done.

same as a lunch box locker.  remove 3rd memeber,  remove carryer, open it, put in spool,  reinstall everything.  thats a cut down list of stuff.  but if you know what you doing then you can do it.

stu

then bring it to some one who does.  you don't wana start taring into the rear without knowing what to do.

stu