Device for connecting suspension system components for axle housing

A method of welding an axle connection device to an axle housing, said axle connection device having a base that includes first and second base end portions separated by a base waist portion, said first base end portion including a first laterally extending side rim, first and second longitudinally extending edges positioned on opposite sides of said device and first and second corners positioned between and adjoining said first side rim with said first and second longitudinally extending edges, and said second base end portion including a second laterally extending side rim, third and fourth longitudinally extending edges positioned on opposite sides of said device and third and fourth corners positioned between and adjoining said second side rim with said third and fourth longitudinally extending edges, said method comprising the steps of:

• beginning a first weld run at a first weld run beginning point positioned along said first longitudinally extending edge of said first base end portion;
• continuing said first weld run along said first longitudinally extending edge towards said first corner to a first weld run first end point positioned longitudinally inward of said first corner;
• turning said first weld run back onto itself at said first weld run first end point and extending it along said first longitudinally extending edge to said first weld run beginning point to form a first double-pass weld portion for said first weld run;
• continuing said first weld run along said first longitudinally extending edge from said first weld run beginning point, along said base waist portion and along said third longitudinally extending edge of the second base end portion to a first weld run second end point positioned longitudinally inward of said third corner;
• turning said first weld run back onto itself at said first weld run second end point and extending it along said third longitudinally extending edge to a first weld run termination point positioned along said third longitudinally extending edge to form a second double-pass weld portion for said first weld run;
• beginning a second weld run at a second weld run beginning point positioned along one of said second and fourth longitudinally extending edges;
• continuing said second weld run along said one of said second and fourth longitudinally extending edges towards one of said second and fourth corners to a second weld run first end point positioned longitudinally inward of said one of said second and fourth corners;
• turning said second weld run back onto itself at said second weld run first end point and extending it along said one of said second and fourth longitudinally extending edges to said second weld run beginning point to form a first double-pass weld portion for said second weld run;
• continuing said second weld run along said one of said second and fourth longitudinally extending edges from said second weld run beginning point, along said base waist portion and along another of said second and fourth longitudinally extending edges to a second weld run second end point positioned longitudinally inward of another of said second and fourth corners;
• and
• turning said second weld run back onto itself at said second weld run second end point and extending it along said another of said second and fourth longitudinally extending edges to a second weld run termination point positioned along said another of said second and fourth longitudinally extending edges to form a second double-pass weld portion for said second weld run.

An axle connection device welded to an axle housing to permit a vehicle suspension system to be connected to the axle housing, comprising:

• a base having first and second base end portions separated by a centrally positioned base central portion;
• said first base end portion including a first laterally extending side rim, first and second longitudinally extending edges positioned on opposite sides of said device and first and second corners positioned between and adjoining said first side rim with said first and second edges;
• said second base end portion including a second laterally extending side rim, third and fourth longitudinally extending edges positioned on opposite sides of said device and third and fourth corners positioned between and adjoining said second side rim with said third and fourth edges;
• a plane projecting from said base, said plane having a plane central portion and first and second plane end portions separated thereby and positioned at opposite sides thereof;
• said first plane end portion having a first opening extending through it;
• said second plane end portion having a second opening through it;
• a first weld run extending along portions of said first and third longitudinally extending edges between a first weld run first end point positioned along said first longitudinally extending edge longitudinally inward of said first corner and a first weld run second end point positioned along said third longitudinally extending edge longitudinally inward of said third corner;
• and
• a second weld run extending between a second weld run first end point positioned along said second longitudinally extending edge longitudinally inward of said second corner and a second weld run second end point positioned along said fourth longitudinally extending edge longitudinally inward of said fourth corner.

An axle connection device adapted to be connected to an axle housing to permit a vehicle suspension system to be connected to the axle housing, comprising:

• a base having first and second base end portions separated by a centrally positioned base central portion;
• a portion of the device extending generally normally and projecting from said base, said portion of the device having a central portion and first and second end portions separated thereby and positioned at opposite sides thereof;
• a first rounded boss extending from said first end portion of said portion of the device having a slot extending through it to accommodate axle mismatch;
• and
• a second rounded boss extending from said second end portion of said portion of the device having a slot extending through it to accommodate axle mismatch.

An axle connection device adapted to be connected to an axle housing to permit a vehicle suspension system to be connected to the axle housing, comprising:

• a base having first and second base end portions separated by a centrally positioned base central portion;
• a portion of the device extending generally normally and projecting from said base, said portion of the device having a central portion and first and second end portions separated thereby and positioned at opposite sides thereof;
• a first rounded boss extending from said first end portion of said portion of the device having a slot extending through it to accommodate varying pinion angles and axle mismatch;
• and
• second rounded boss extending from said second end portion of said portion of the device having a slot extending through it to accommodate varying pinion angles and axle mismatch.