What kind of diff cover? Im running a SOLID aftermarket cover that sitcks out pretty far.i used 1.5 tubing for my tie rod and it doesn't contact the diff cover enough to worry about putting an arc in it. i have ran mine like this a few times and the only thing that has happened was the paint was rubbed off my tie rod.
The only reason Im set on the tubing is because, I got 8 3/4" chromoly heims 4-LH 4-RH, lock nuts, Bungs for 1.5x .250, Missalignment washers, reducers, and the DOM tubing. All for about 100 bucks. Notching the cover could work though... Never thought of that, thats a good idea thanks..im running my stock cover still. you could always notch the diff cover if you are set on running the 1.5" tube.
well there's 2 ways i can think of that will work.Can you please explain the proper way to go about this? Id really like to avoid it fracturing.
wow that sounds like way more trouble then its worth. How about a stock cover and a rock guard on the bottom?well there's 2 ways i can think of that will work.
you could notch out the cover and put a piece pipe in it's place and if you are worried about it cracking then just gusset the inside of the cover on the non-ring gear side.
or (this would be easier) you could cut the front out of the cover then weld a new plate back in just get it back far enough to clear everything.