Cj737, thank you for the advice on consumables and power to use im going to experiment on the bit i cut off which has similar dimensions also i Will be working slightly to the side of the weld so if any drops i wont be underneath it. Ive found a way using some big cable ties to make a sort of sling ...

Thanks to all of you who have replied, the safety aspect of me welding this is very small as it drives the front wheels the shaft is bolted at the front and welded at the back. The spline adaptor is about 5” long with 2” of splines about an inch of no mans land and then about 2” of solid steel that ...

Im fairly new to welding and while I'm able to put down a reasonable weld im about to undertake a repair to the front prop shaft on my bmw x5 the problem i have is the Tube of the prop shaft is about 30mm diameter and the wall is 2.4 mm thick but the new spline adaptor i need to weld in is solid ste...