Diff fabrication.

[aussiejoeblow]

Hi all, a new member here. I mainly joined for the hercus section but I'm open to learning other stuff :D I tinker with custom 4x4's and thought I would show one of the custom diffs I make to suit Suzukis. The main reason I do this is to mix and mach axles and different widths to suit the requirements.


The concept.....

http://i70.photobucket.com/albums/i86/jmleban/components.jpg

http://i70.photobucket.com/albums/i86/jmleban/diff1.jpg

The work.....

http://i70.photobucket.com/albums/i86/jmleban/PIC_0008-1.jpg

http://i70.photobucket.com/albums/i86/jmleban/PIC_0010.jpg

The front A-frame for the suspension...

http://i70.photobucket.com/albums/i86/jmleban/aframe1.jpg

http://i70.photobucket.com/albums/i86/jmleban/yellowthingfrontdiffjig.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010162.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010167.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010169.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010175.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010190.jpg

[aussiejoeblow]

And the last of it......

http://i70.photobucket.com/albums/i86/jmleban/PIC_0082-1.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010120.jpg


http://i70.photobucket.com/albums/i86/jmleban/P1010014.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010016.jpg

http://i70.photobucket.com/albums/i86/jmleban/P1010023.jpg

The workshop....

http://i70.photobucket.com/albums/i86/jmleban/P1010126-3.jpg

http://i70.photobucket.com/albums/i86/jmleban/shed4.jpg

[Yonnee]

Hey Aussie Joe, you certainly know how to make a first impression... and probably a few people quite envious. Welcome aboard.

Love your work!!

Bring on more pics.

Y.

[buildspacetrain]

Yes Yonnee, but can he build a decent trailer?!!!!!!!

[nihilism]

Nice work. Wish I was that skilled.

[surfin]

Awesome work.

How did it work out when put into action?

[Harry72]

Christ whats this Suzi got a gen3 chev in it?

[UglyDan]

Looks really well thought out and great finish to it. Well done and hope to see more of your handywork:2tsup:

Cheers

[jatt]

Ok you got my attention:)

Definetely looks the goods. Makes my welding look a bit ordinary.

[aussiejoeblow]

Thanks for all the comments guys. Trailer building is something I'm yet to try (Suzuki's don't tow so well). These diffs are just used with zook engines, though I do have a Toyota 4.0 litre V8 powered Daihatsu Rocky in the shed! I tinker with custom building drivelines to whatever the spec might be......and it keeps me out of trouble.

I also make some custom t/cases so we can run twin transfers. Here are some pics.

http://i70.photobucket.com/albums/i86/jmleban/IM000152.jpg

http://i70.photobucket.com/albums/i86/jmleban/IM000158.jpg

http://i70.photobucket.com/albums/i86/jmleban/IM000160.jpg

http://i70.photobucket.com/albums/i86/jmleban/IM000151.jpg
Reducing the length of the box by half.

http://i70.photobucket.com/albums/i86/jmleban/IM000167.jpg
New shift housing.

a new flange needs to be made, consists of a 'blank' and a broached 33 spline shaft.

http://i70.photobucket.com/albums/i86/jmleban/IM000162.jpg

http://i70.photobucket.com/albums/i86/jmleban/IM000117.jpg

http://i70.photobucket.com/albums/i86/jmleban/PIC_0035.jpg
New output shaft hase been made. The welded spline section has four keyways as well as the weld holding it together. It is the sent off to be hardened.

http://i70.photobucket.com/albums/i86/jmleban/PIC_0023-1.jpg

http://i70.photobucket.com/albums/i86/jmleban/PIC_0029.jpg
New seal housings before and after tigging.

[Harry72]

You dont muck about!