**edit** diff is now on Ebay....
http://cgi.ebay.com/ebaymotors...wItem
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Well since my brother is a CNC machinist and I didn't want to pay over $1000 to have a reinforced differential I decided to put him to work. So I picked up a stock low mileage 4.10 diff to do some "testing" with before I reinforce the 4.77 diff that is currently in my car. This has been a fairly long process and we are finally making some headway.

Anyways, here's some pics of the progress so far...


Stock cap machined down and the steel reinforcement cap. Also in the pic the new, longer tab for the diff bearing "adjusters".





Very tight tolerance between the two caps










And my brothers own personal Makino 3-axis CNC machine



Gonna pick up some bolts tomorrow, go through the diff and put it all back together.

More to come....



Modified by 29psiHybrid at 8:18 PM 10/11/2008

 

Won't that bolt in the center of the cap cause a "weak point"?

 

i wish i had access to such nice machinery. i'd be making all kinds of stuff.

the diff look very nice btw.

 

what grade steel bolt are you using for that cap? what kind of torque specs will you use to tighten it down with?

did he machine both surfaces or just the new cap? shouldn't both be done so they mate perfectly?

 

did you read the post or looked at the pics.
he did machine the oem cap to match reinforce cap.
look at the first pic

 

looks bangin robbie...and i replied to your pm

 

What do the comptech re-enforced diff's look like? I have never seen one from the inside.

 

iirc they look pretty much like that does

 

They're similar but not quite as "beefy"....



As you can see the reinforcement cap doesn't completely contact the stock cap...

 

is there a way to maybe notch the stock housing & put a mortise & tenon connection in there?

 

Very interesting post. Sad how Honda could have very very easily done this instead of skimping like that did..

 

Oh gotcha... Is that center hole already present in the factory cap?

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by White Smoke &raquo;</TD></TR><TR><TD CLASS="quote">Oh gotcha... Is that center hole already present in the factory cap?</TD></TR></TABLE>

Yes. And with being a cast steel cap it is very weak right there.

 

so just a simple reinforcement cap is going to keep things from what? is the oem cap prone to breaking? I haven't done to much research on beefing the diff so I'm just curious now.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by megalomaniac001 &raquo;</TD></TR><TR><TD CLASS="quote">is the oem cap prone to breaking?</TD></TR></TABLE>

Yes... The cap should help keep the pressure under control. You can't tq that center bolt to much though... Why exactly did you incorporate it into you design? Is it for the factory bearing adjusters? Didn't want to put it off to the side like the comptech?

You know you are going to have to sell these

 

ive blown up two rear ends at the track already. i broke the carriers on one and the gears on the other.

 

looking good man. glad to see someone out there with determination

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by White Smoke &raquo;</TD></TR><TR><TD CLASS="quote">

You know you are going to have to sell these </TD></TR></TABLE>

he can't just sale the reinfore cap. the stock cap have to be machine to match the reinforce cap.

 

Good **** Lets us know how it turns out. You dont know u might be getting a new job

 

Why not just remake the enitre cap with the extra support built in instead of just bolting on the reinforcement? (i am no metal machinest expert so i am not sure if it can be replicated perfectly or not.)

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ReddotsS2K &raquo;</TD></TR><TR><TD CLASS="quote">Why not just remake the enitre cap with the extra support built in instead of just bolting on the reinforcement? (i am no metal machinest expert so i am not sure if it can be replicated perfectly or not.)</TD></TR></TABLE>

the stock cap are threaded on the inside, when bolted on the diff carrier the thread have to line up perfectly. there's really no way to make a completely new cap with thread on it to match up with the diff carrier.

 

Thanks guys!


<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by White Smoke &raquo;</TD></TR><TR><TD CLASS="quote">

Yes... The cap should help keep the pressure under control. You can't tq that center bolt to much though... Why exactly did you incorporate it into you design? Is it for the factory bearing adjusters? Didn't want to put it off to the side like the comptech?</TD></TR></TABLE>

Because the hole was already in the middle of the stock cap so we're gonna use the adj. ring tab bolt to secure the caps at the middle, and add some material in there. Believe me, this reinforcement cap is not going to break with that hole in there.


<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by White Smoke &raquo;</TD></TR><TR><TD CLASS="quote">
You know you are going to have to sell these </TD></TR></TABLE>

Always a possibility later on...

 

looks good cant wait to see outcome

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by White Smoke &raquo;</TD></TR><TR><TD CLASS="quote">You know you are going to have to sell these </TD></TR></TABLE>

already got dibs on #2

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by rice4life &raquo;</TD></TR><TR><TD CLASS="quote">

he can't just sale the reinfore cap. the stock cap have to be machine to match the reinforce cap.</TD></TR></TABLE>

Obviously, but people can send there caps to him or he can buy stock from the dealer