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View Full Version : My DIY 8.8 diff cover....



robselina
01-16-2005, 11:47 PM
This was a little more of a PITA than I expected, but it came out alright. Probably do a little more sanding then throw some flat black on it. One thing's for sure is it's a hell of a lot stronger than that plastic thing they gave me stock! :)

BTW it's all 1/4"

http://www.nmt.edu/~rselina/diffcover1.JPG
http://www.nmt.edu/~rselina/diffcover2.JPG
http://www.nmt.edu/~rselina/diffcover3.JPG
http://www.nmt.edu/~rselina/diffcover4.JPG
http://www.nmt.edu/~rselina/diffcover5.JPG

Swamp boy
01-17-2005, 12:01 AM
Damnit.. Thats not bad..

As always. Great Job...

ELLLLLIOTTTTT
01-17-2005, 02:35 AM
put a fill hole on it yet? looks really good. the stock cover is pretty weak, i think 1/4" got the job done.

LouisianaZJ
01-17-2005, 03:02 AM
why?
the filler plug is on the housing

looks good

might want to add some more 1/4" to the bottom lip to resist peeling it back


the cover on my rear 44 is paper thin as well. i bent the lip to shit just trying to get it off to change the gear oil. my stock D35 cover was thicker.... i should be recieving a new D44 cover this week though 1/2" ring and 1/4" face

kida a dumb question but what kinda disc did you use to grind down the welds like that?

OverkillZJ
01-17-2005, 03:03 AM
I like :)

Nordic1
01-17-2005, 03:27 AM
I like as well

robselina
01-17-2005, 11:46 AM
Thanks guys.



might want to add some more 1/4" to the bottom lip to resist peeling it back

....

kida a dumb question but what kinda disc did you use to grind down the welds like that?

I'm tempted to add to the lower lip too, though what I've done is the diff cover is 1/8" above the lower edge of the pumpkin, so it doesn't have a lip to catch. Dunno, we'll see, maybe I'll get ambitious. :)

As for grinder, used a 4" grinding wheel then used a 4" coarse sanding wheel. It's basically just a ring of sanding paper so it' flexes nice over edges and stuff. They sell them at Home Depot.

BigDaveZJ
01-17-2005, 12:26 PM
then used a 4" coarse sanding wheel. It's basically just a ring of sanding paper so it' flexes nice over edges and stuff. They sell them at Home Depot.

I believe they're referred to as "flapper wheels," they work pretty well for finishing work.

ELLLLLIOTTTTT
01-17-2005, 01:22 PM
why?
the filler plug is on the housing


ya learn somethin new everyday

Jim311
01-17-2005, 01:43 PM
Sweet. But if I were going to make a new cover, I'd have shaved the bottom of the pumpkin. I might do that to mine.

robselina
01-17-2005, 01:53 PM
Sweet. But if I were going to make a new cover, I'd have shaved the bottom of the pumpkin. I might do that to mine.

I let rocks do that for me :twisted:

(seriously, I think the D60 pumpkin on the waggy is about 1/4" thinner on the bottom now thanks to rocks working at it)

Grand Taz
01-17-2005, 03:10 PM
Nice work Rob, looks good.

LouisianaZJ
01-17-2005, 05:36 PM
why?
the filler plug is on the housing


ya learn somethin new everyday
i thought you said you already had an 8.8 :?

nathaniel
01-17-2005, 08:38 PM
Next time to make it a little easier you could probably use jeepnmatt on ju and pirate rock ring for the 8.8.
Looks good.

ELLLLLIOTTTTT
01-17-2005, 08:40 PM
why?
the filler plug is on the housing


ya learn somethin new everyday
i thought you said you already had an 8.8 :?

i do...but obviously havent done anything with it because it is not yet under my jeep. its sitting at a local guys shop waiting on me to get $$$ for gears, locker, etc.

robselina
01-18-2005, 01:06 AM
Next time to make it a little easier you could probably use jeepnmatt on ju and pirate rock ring for the 8.8.
Looks good.

won't work. The thing didn't have the usual thin tin diff cover, it was littlerally plastic/fiberglass or something like that. It would chip if you pried on it. The only metal part were these two tabs infront of the tubes that you were meant to use as a pry point. Anyway, the lower lip of the thing already had this reinforced section (all fiberglass still) so you couldn't fit a standard rock ring or anything like that....

JpRngr
01-18-2005, 02:14 AM
You could have used the rock ring for the basis of your cover.

BTW, looks good! :D


Corey

nate
01-18-2005, 10:57 AM
Yeah that fiberglass cover is crap. I had the same thing, and I cracked it trying to pry the cover off. Went to the junkyard and it just so happen they had a metal one lying on the floor in the shack they use to pull axles apart.

nathaniel
01-18-2005, 06:47 PM
You could have used the rock ring for the basis of your cover.

BTW, looks good! :D


Corey

Thats what I meant.