Diff Cover Plating

[Hooper]

If I am not the worst excuse for a welder there ever was, than I don't know who is.

Finally got it all done though. 4 strips of either 1/4" or 3/16" plate (Didn't measure, so I don't know which it is), welded to the hump of a second diff cover, then that cover glued/welded to my existing cover...

Should keep me from punching in my diff cover. Now I can rip the whole axle off with my drive by braile approach to wheeling... <chuckle>



I also welded a couple support brackets onto my tailpipe so they wouldn't rattle as much. Welded my drop shock towers to my spring plates, although the little 110 mig I was using really wasn't up to the task. Still, they have been attached via bolts for a couple years now, so the welding is just added insurance.

Ugly welds though, but, they are mine...

I'd like to add a few gussetts to my cage before the trip at the end of July, but we'll have to see how time works out. I'll farm that welding out to an expeienced welder. I don't trust my life to my welds...

[binderbound]

Hoop, you might regret only going half way up the cover. You'll probably end up folding the cover in half.

This is our cover. 3/16 thick cover with 1/4 thick plate welded to it. Never mind the ruler.

[Hooper]

Originally Posted by binderbound

Hoop, you might regret only going half way up the cover. You'll probably end up folding the cover in half.

This is our cover. 3/16 thick cover with 1/4 thick plate welded to it. Never mind the ruler.

See, nice and neat, clean even.. <chuckle>

Maybe on the next one...

Remember, my cover is doubled up though. So, I have two 1/4" covers, plus the plate on top of that...

DK how well it will work. You are probably right I should have gone all the way up....

[binderbound]

Originally Posted by Hooper

See, nice and neat, clean even.. <chuckle>

Maybe on the next one...

Remember, my cover is doubled up though. So, I have two 1/4" covers, plus the plate on top of that...

DK how well it will work. You are probably right I should have gone all the way up....

Where did you get a 1/4 thick cover? thickest I could find was the Ford high fill plug, 3/16 cover.

[Hooper]

Originally Posted by binderbound

Where did you get a 1/4 thick cover? thickest I could find was the Ford high fill plug, 3/16 cover.

No, I typed wrong. Two covers, *making* 1/4", I think. I didn't measure either, but they are both thin covers...

Make more sense now..?

[binderbound]

That is better.

[justscoutin]

i've got part of an 86 bronco d44 cover/arm assembly. i'm going to trim it off around the diff and have a 1/4" cover for mine. its pretty stout.

[Hooper]

Originally Posted by justscoutin

i've got part of an 86 bronco d44 cover/arm assembly. i'm going to trim it off around the diff and have a 1/4" cover for mine. its pretty stout.

That is where my idea started. Just trimming and doubling up the cover. But then, I got to looking at it, and thought it wouldn't be too hard to add some plate to this cover while I was cutting it up, to reinforce it even more... So, I grabbed the grinder and some steel strap. Next time, I will get some long, 3 inch strap, like Binderbound used, and go top to bottom with it.

My concern with using wider strap like that is that with only my little 110 mig I was using, and my poor welding skills, it might be tough to weld the sides of the strap to the cover. I could weld the ends, but the sides would be problematical. So, with my skills, it was easier to use the narrower strap, that conformed to the diff cover a bit better.

Binderbounds is definitely cleaner and stronger though... But, what I ended up with is a far cry better than just the stock thin cover...

[binderbound]

I too, was concerend about just welding the ends. I also used just a 110 welder. I took the piece of straight flat bar, welded the bottom of it to the bottom of the cover, then had carl run the hammer (cuz he's stronger) and I ran the torch. We just heated and beat, heated and beat, until the other end made it to the top of the cover. During the whole process the botom weld never looked like it was ever gonna break. Just for kicks, as soon as I finished welding the top end down we turned the cover over to see what the metal underneath looked like. It was on the verge of melt through. I think the penetration was good on that one

[Hooper]

Originally Posted by binderbound

I too, was concerend about just welding the ends. I also used just a 110 welder. I took the piece of straight flat bar, welded the bottom of it to the bottom of the cover, then had carl run the hammer (cuz he's stronger) and I ran the torch. We just heated and beat, heated and beat, until the other end made it to the top of the cover. During the whole process the botom weld never looked like it was ever gonna break. Just for kicks, as soon as I finished welding the top end down we turned the cover over to see what the metal underneath looked like. It was on the verge of melt through. I think the penetration was good on that one

So you welded and then bent... looks like it worked well. You didn't weld the edges at all, just the ends? I flipped my cover and had good discoloration all the way around my seams, but it is not hard to get penetration on the thin cover I was working on...

In any case, it is just a little added protection, especially for creek and river crossings where it is tough to see the rocks...

Mine's not as pretty, but I think it will do the job well enough.

But, if it is not one thing it is the next. Went up and grabbed a spare 35" tire from lilredzuk, to replace the 33" spare I have now. About a 20 minute drive each way. When I parked, I noticed that there was fluid on my tire, and a small puddle about 3 inches across on the ground. Passenger rear tire, inside sidewall. I thought at first I might have blown a wheel brake cylinder, but closer inspection revealed it to be diff fluid. I have inner seals in my diff, bearings are lubed with axle grease. So, evidently my inner diff axle seal has sprung a leak. It is not that old of a seal. Less than a year, and only a couple hundred miles on it at the most... Outer seal on the axles are about the same age... Looking at the tire, I can see what looks like oil that is a bit older, not fresh anyway.. so, maybe it has been leaking for a while, but it just leaked more with the longer drive today. Today was about the farthest I have driven it in about 4 or 5 months.

Guess I will just have to keep an eye on my diff fluid now... <sigh>

[Binder]

Looks good Hoop. I think it will work fine.

[Hooper]

Originally Posted by Binder

Looks good Hoop. I think it will work fine.

Thanks. You, probably better than anyone, know just how often I smack the diff cover.. .<chuckle>

[Shadow man]

Originally Posted by binderbound

I too, was concerend about just welding the ends. I also used just a 110 welder. I took the piece of straight flat bar, welded the bottom of it to the bottom of the cover, then had carl run the hammer (cuz he's stronger) and I ran the torch. We just heated and beat, heated and beat, until the other end made it to the top of the cover. During the whole process the botom weld never looked like it was ever gonna break. Just for kicks, as soon as I finished welding the top end down we turned the cover over to see what the metal underneath looked like. It was on the verge of melt through. I think the penetration was good on that one

Thats how I do them too. I have had some direct hits on the front cover that has hurt! Dead stops! It will take quite a beating. Now break out the sawzall and trim those bottoms off.

[Hooper]

Originally Posted by Shadow man

Thats how I do them too. I have had some direct hits on the front cover that has hurt! Dead stops! It will take quite a beating. Now break out the sawzall and trim those bottoms off.

I shaved the lip off mine when I did my front locker install. Even installed a front diff drain plug... <chuckle>

Shaved the rear pumpkin at the same time...