Last night I stayed after work to make the passenger side 3-bolt flange axle. The cup shifted in the chop saw and ruined the cut. We put the cup in a lathe and squared it up, but we shortened the original cut(factory stamped line) by about 3/16". We lined up the flange, and welded it right in the lathe, so it's very straight, but I'm wondering if the shorter cut is going to cause a problem. I don't think 3/16" is going to, but I just want to check first before I do the rest.

I don't mean to be a ass but that weld don't look like its going to be very strong

I agree about the weld. I'm no where near an expert. but it doesn't look like you got very good penetration.

It seems to be good, there's a good heat mark all the way around on the inside except for the three tacks. I had a couple people look at it today and they were questioning it too. The welder ran out of gas just before the big welds. It was too late after the fact, and I'm not buying more parts to make another so I guess it will have to do 

more heat and less wire needed
28 years experience

But we all like pretty welds that sit on the surface ........don't we 

3/16" shouldn't be a big deal but it just means that you have a little less available before it could pull out under full droop.

You will be fine. I dont belive 3/16 is enough to make a difference. The weld could be done better but from what I see in the photo I belive it will hold.

i did that mod to my old vitara. not the widening, but to run 2 left hand side shafts.

2nd trip out, i snapped the stub off.

made a new one the same way, and the very 1st trip out, snapped the stub off again.

everytime i had to pull the front 3rd out to get the splined stub out of the diff.

i was told that the weld was plenty strong enough, but the heat through it wasn't good and thats what let them break. my mate who is a welder by trade did it proper the 2nd time around, pre heating before the weld, weld 1/3, cool, pre heat, weld 2/3, cool, pre heat, weld rest cool. left for a couple of days before fitting, and i still broke it.

the right hand side of the diff housing needs another support bearing like the left hand long side.

good luck anyway.