Can't Get Enough
Join Date: Sep 1999
Location: The Plywood State.... Florida
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Re: BTF DIY diff cover
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.