A couple weeks ago Bluetorch Fabworks. had an open house/jeep build. Pirate4x4 links are here and here. Man, they do some awesome work. Anyway, while i was there I picked up their DIY differential cover. The outer ring is 3/8" and the rest is 1/4. Very beefy. The fit of the pieces was dead on with no prep required before welding.
LEVE, I have more pics if you want to do an article.
That cover came out great, looks nice.
Would you mind letting us know how much $, and how much Time you have in it?
That is a Mod that I have been thinking of doing on my Front D44.
[img]/ubbthreads/images/graemlins/tongue.gif[/img] Great looking setup!!! [img]/ubbthreads/images/graemlins/cool.gif[/img] A couple of questions????? (1) Do you have to "face" the part on a surface grinder to get the gasket surface flat after welding? Surely the part is going to warp at least a little? (2) Do you need to use socket head screws where there is insufficient clearance to swing the hex head cap screws (bolts)? [img]/ubbthreads/images/graemlins/tongue.gif[/img]
I did not have to surface mine. I thought about that, so I bolted it to a junk housing to help keep it from warping. I tacked it together and moved all around welding 1 to 2 inches at the time, but did not wait for the whole thing to completely cool. Just tried to heat it fairly evenly while keeping it as cool as you can while welding. I think you could get away with clamping it to a welding table or maybe even not clamping if you took the time to weld a little, let it cool and weld a little more. Maybe I got lucky? If you want to use bolts, spot facing might get enough clearance. Not sure though. I am using socket head bolts. They will clear. Covers from different axles have some more clearance for the bolts, but the 8.8 is close. After I finish a few other projects, I am getting a Dana 44 cover for the front. We'll see how that one goes.
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BTF DIY diff cover 
Linear Mode
