I started by cutting out the damaged area on both housings and ground it flat on my bench grinder.
The flange I cut off is the only thing that keeps the inner race in contact with the outer race of the joint, so I needed to add more metal.
On replacement cv joint boot kits, they send replacements for these. So I cut off the top of them like so.
Tacked them up
Finished welding around the perimeter. The bead is pretty tall because I didn't grind down the welds as I went, as you usually would with sheet metal. I will eventually be grinding them down flush to check for voids and re-weld as necessary, but figured this was enough work for today.
Almost ready for reassembly.
Today I also installed drawer liners in my welding cart and bought a big moving blanket at harbor freight that I'm going to turn into a cover for it.
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