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02-05-2006 02:15 PM

Diff Rebuild

Manufactured the 4 bar support bracket from ¼" S/Steel flat plate.
Photo 1 drilling the holes after cutting and linishing
Photo 2 tack welded the first side on
Photo 3 temporary bars add for setup
Where did January go?

(click photo to enlarge)

[Entry #32]

12-23-2005 07:50 PM

Diff Modes

I have decided to manufacture the diff tubes from Stainless Steel. I bought 3" schedule 80 tube and got two pieces of 3/8" plate profile cut for the inside flanges. I used ¼" plates to make the outside flanges. I machined the ends to fit the bearing inside, then tig welded the flanges inside and outside to the tube. I have used ½" grade 8.8 S/Steel bolts and doweled the top for alignment. I think I have gone overboard on strength once more.
These should polish up very nicely. Merry Christmas to all.

(click photo to enlarge)

[Entry #31]

12-23-2005 07:46 PM

Diff Modes

After looking at many diffs I decide to have a bolt on tube design. First I had to manufacture the flanges that would be pressed into the diff head these I made from ¾" thick plate welded to schedule 80 boiler tube. Drilled and tapped with ½" threads. I pressed these into the diff heads and welded them on.

(click photo to enlarge)

[Entry #30]

11-17-2005 03:35 PM

Diff Mods

Photo No.1 Removed the drive shaft clamp bracket then remove the pinion.
Photo No.2 Shows the tubes removed from the diff head. It took a lot more effort than anticipated to remove the tubes. Was told to put the diff head into a large vice and rotate the tubes and they will come out. Not true after borrowing a gas plant from a mate and heating, still could not turn the tubes. Reverted to the railway tradesman method, big sledge hammer a lot of sweet and they finally came out with the aid of heat. I am thinking about replacing them with S/Steel tubes, as there are allot of dings on the tubes now.
Photo No.3 Shows the tubes battered and dinged. Stainless steel will look a lot better.

(click photo to enlarge)

[Entry #29]

11-14-2005 05:51 PM

Diff Mods

Photo No.1 shows the half axle being removed from the tube.
Photo No.2 shows the half axle removed.
Photo No.3 first pilot hole drilled through the welded plug. I will use a ¾" hole saw to remove all the welding.

(click photo to enlarge)

[Entry #28]

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