possible project - rear differential cover

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Jan 30, 2011 | 11:48 PM

Danilo

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goat hugger

Joined: Apr 2010

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From: Fontana

possible project - rear differential cover

was wondering if anyone had fabricated their own rear diff cover.

i am thinking of fabricating my own rear diff cover for my 10.25 axle so that i have more fluid capacity and want to install a diff temp gauge.

checked out the after market ones and they are to much money for my taste.

any and all input is appreciated.

thanks so much.

Feb 1, 2011 | 08:59 PM

xirxious

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I work on cad all day and was tempted to design one, just haven't had time to measure one. My plan was to increase the fluid capacity and add a drain plug. I'd also add fittings for a temp gauge and possibly plug holes to add cooling lines. I had an old pump from a stock car somewhere, but they rub a lot lighter weight fluid.

Feb 1, 2011 | 09:21 PM

Danilo

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goat hugger

Joined: Apr 2010

Posts: 91

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From: Fontana

that sounds awesome! i am not CAD savy but i am going to make a diff cover even if it looks a little freankenstein like when i am done.

the stock cover is 1/16" thich, i plan on using 1/8" thickness when i make my cover.

what do you think is a good depth for the cover? the stock cover is about 3 1/8" in height when you lay it flat. i was thinking about adding another inch but not sure if that would be too much.

i would really like to hear what your plans were for using a pump to cool the oil.

would the pump be electric?

where would the oil cooler be mounted?

Feb 1, 2011 | 09:48 PM

82F100SWB

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Joined: Jan 2000

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From: Dryden, ON, Canada

How about a weld it yourself kit? Blue Torch FabWorks, Inc.
You can also buy just the outer ring, which will make your life much easier if you decide to fab the cover yourself.
Blue Torch FabWorks, Inc.

Feb 2, 2011 | 12:55 AM

xirxious

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The one I have is belt driven, not sure about where to put the cooler. Tex racing makes a sweet internal mechanical pump, but it's probably not cheep. Typically they run thinner oil in racers. I was thinking eighth or even quarter inch plate. I'd draw out the shapes sand have them cut by a water jet somewhere. My main concern is how to keep the seal face flat when welding it.

Feb 2, 2011 | 12:31 PM

Danilo

Thread Starter

goat hugger

Joined: Apr 2010

Posts: 91

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From: Fontana

hey 82f100swb i had no idea that those two items existed as kits. i am considering buying the ring.

i have decided to go with 3/8" steel for the cover. to keep it from warping when welding i think i can either tack weld the ring to keep it flat or bolt it to something to get the same results.

i am looking into an electric pump right now. i found what i thought was perfect. the only drawback is the pump can't handle the viscosity of the oil.

i will definitely post if i find something.

Feb 2, 2011 | 01:28 PM

xirxious

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The thinking is if you cool it better, you can use lower viscosity. A higher weight grease heats up so much, it is close to 10w-30 when at operating temp. a bigger sump is more oil to soak up the heat and a cooler keeps it constant. Obviously its probably over kill, but I usually pick some small project to 'overdesign' and the info is useful to someone out there.

NASCAR racers use a small oil pump mounted inside the diff and driven off the pinion. Way higher tech, expensive and commercially available only for the 9" style.
That ring looks like a good start. I wonder if someone can surface grind it when I'm done to ensure its flat and leakproof?