AOD Dipstick Needs To Be Shortened

[RooDog]

OK, Guys....
I have an AOD from a straight six truck behind my project 302 and it seems to be way longer than my liking. I would like to shorten it about 4-6 inches. My thinking is to cut the tube from the straight section at the top. And then remove an appropriate section from the stick near the top where it would not be required to flex. I know this is tempered steel so welding could ruin that temper which is why I want to stay at the top, just below the handle, where it can remain rigid. I plan a lap joint and to just mig weld the edges keeping rest of the stick cool with a wet rag. I do have an aftermarket braided SS dipstick assy, but it is out of character with my 70's build plan. Any thought or comments from y'all. I know somebody's will have something to say, and really do welcome the input this time....RooDog....

[Tinker]

You might be able to use small rivets since your lapping it a few inches. The tempered steel wont weld well (it will become very brittle and break).

http://www.lincolnelectric.com/en-us...ls-detail.aspx

[RooDog]

Rivets would be good if I can get a drill bit through the stick, I haven't checked the hardness. I also wonder if I could retemper the steel after welding, as you would do a knife blade. I'll need to try and find an extra stick to practice on...RooDog

[Tinker]

I once tried to tig weld a broken stick (butt weld). It would just keep breaking, it became very brittle. Maybe a lap weld will work for you. My understanding is to preheat and then slow the cooling process. A couple of rivets would be a fast, easy, and secure way to do it. IMO

[Lanny]

Can you just cut the same amount from the bottom of the stick as you
remove from the tube, then scribe your add fluid line and scribe your
full line at the appropiate places on the stick.











.

[RooDog]

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Lanny......
That's probably the best route. I can use my dremmel and sand blaster to mark the hardened steel....RD

[jimc9990]

I have cut both transmission and engine oil dip sticks tubes. I always just cut the lower end of the stick and make two new marks , one at full and another at one qt. low. I never have tried to weld one but i did buy a car that had a welded one and it never did break during the time i had it.__JIM

[Motorhead6]

Braze it. It may look a little funky but only you will see it and then only on the rare occasion that you are checking the fluid level. If you need to weld it, re heat with a torch to a cherry red and then let it cool slowly. You can control the cooling rate by moving the torch away little by little until the color goes away and then let air cool.

[scrapiron]

Silver Solder it,,,,low temp

[RooDog]

OK Fellas.....
Here is my final solution. Thursday afternoon I discovered in my parts stash a dipstick, I presume was left over from a failed FMX, which turned out to be 4 inches shorter than the AOD's stick. The plan became to simply section out 4" from the tube near the top. I couldn't just cut off the top of the tube because the opening was slightly flared and fluted to fit the dippy, so I took out 4" just below the opening so I could dremel out the inside should there be too much weld penetration. So, even though the two sticks when placed side by side only differed by 4", when inserted the "new" stick's full mark was 1/4" deeper into the tranny. It also struck the bottom of the pan. I had to go back and add that 1/4" to the tube. Not a problem as I hadn't welded anything yet. After welding the tube, the recycled FMX stick's full and add marks are where they need to be. A fresh coat of rattle can black over self etching primer and all is well.....
However, I did not address there original question of how to safely shorten the stick, but it is no longer an issue......Thank y'all for your input.....RooDog

[Motorhead6]

Ford Barn ingenuity at it's best.

[RooDog]

And never toss any FORD or Harley parts while there is still a spark of life left in 'em....Yo?
RooDog