• Welcome Visitor! Please take a few seconds and Register for our forum. Even if you don't want to post, you can still 'Like' and react to posts.

differential cover bash guard

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
last night i made up a bash guard for my new axle so im just posting it up here for feed back. let me know if you see something i should change before it makes it to the paint stage!








 
Last edited:


88_Eddie

Well-Known Member
Solid Axle Swap
Joined
Oct 1, 2009
Messages
6,616
Reaction score
156
Points
63
Location
Raleigh, NC
Vehicle Year
1988, 2000
Make / Model
Ford
Engine Size
2.9L, 4.0L
Transmission
Manual
nice work, looks awesome man

wish i had a torch like that when i was bending my 1/2" solid bar, had to use a handheld propane torch, took forever!
 

alwaysFlOoReD

Forum Staff Member
Forum Moderator
TRS Banner 2012-2015
TRS 20th Anniversary
Joined
Apr 13, 2009
Messages
12,582
Reaction score
3,601
Points
113
Location
Calgary, Canada
Vehicle Year
'91, '80, '06
Make / Model
Ford, GMC,Dodge
Engine Size
4.0,4.0,5.7
Transmission
Manual
2WD / 4WD
4WD
More for aesthetics than anything else, add some horizontal bars [follow the outside edge] to make it look somewhat like a spider web. Maybe use some 5/16" bar that's curved slightly.

Richard
 

4.0B2

Well-Known Member
Supporting Member
TRS Banner 2012-2015
Joined
Sep 24, 2009
Messages
10,700
Reaction score
150
Points
63
Location
Walls, MS
Vehicle Year
1988
Make / Model
Ford
Engine Size
4.0 v6
Transmission
Automatic
that'd be cool..

but regardless- looks good, should be pretty functional to!

and A LOT cheaper than an offroad diff cover
 

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
More for aesthetics than anything else, add some horizontal bars [follow the outside edge] to make it look somewhat like a spider web. Maybe use some 5/16" bar that's curved slightly.

Richard
thats what i was thinking, at least between the two vertical ones on either side of the ring gear. this was all brought on by me almost backing into a rock while trying to hook up to a trailer. that was when i had just rebuilt the axle that is currently in the truck so i wasnt about to take it back out to build one so now that im building another axle i figured i might as well make one this time.
 

Iron Ranger

Run lil' ricer RUN!!
Supporting Member
V8 Engine Swap
MTOTM Winner
Joined
Aug 27, 2007
Messages
1,807
Reaction score
22
Points
0
Age
37
Location
Minnesota
Vehicle Year
1992
Make / Model
Ford
Engine Size
0.040 punched 302
Transmission
Manual
It looks really awesome actually. :icon_thumby:

The only thing I'd do is put 2 more bars from the top to the cage to brace it. Since, if you were to smash straight down onto a rock, the force could bend up the flange surface(s) where the bars are welded. Then it would cause diff leakage.:sad:

Better to over-do it than to wish you over-did it, right? :D




Something like this would help out a bunch.
 
Last edited:

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
well the rods are welded to a plate that bolts on over top of the cover, i had to cut the lip on the cover in the middle and then pound the lower portion of the flange out flat so that the guard could bolt over top of the cover. did i make that confusing enough?
 

alwaysFlOoReD

Forum Staff Member
Forum Moderator
TRS Banner 2012-2015
TRS 20th Anniversary
Joined
Apr 13, 2009
Messages
12,582
Reaction score
3,601
Points
113
Location
Calgary, Canada
Vehicle Year
'91, '80, '06
Make / Model
Ford, GMC,Dodge
Engine Size
4.0,4.0,5.7
Transmission
Manual
2WD / 4WD
4WD
What you're saying is the guard is separate from the cover. That should work to prevent what Iron Ranger was worried about.

Richard
 

Iron Ranger

Run lil' ricer RUN!!
Supporting Member
V8 Engine Swap
MTOTM Winner
Joined
Aug 27, 2007
Messages
1,807
Reaction score
22
Points
0
Age
37
Location
Minnesota
Vehicle Year
1992
Make / Model
Ford
Engine Size
0.040 punched 302
Transmission
Manual
well the rods are welded to a plate that bolts on over top of the cover, i had to cut the lip on the cover in the middle and then pound the lower portion of the flange out flat so that the guard could bolt over top of the cover. did i make that confusing enough?
Oh ya, I didn't see that part! :icon_twisted: It looked like it was welded right to the diff cover.

No, no. Never mind what I said. Your system will work perfectly! :icon_thumby:
 

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
i added some more gusset work to the guard last night, then finished cleaning things up and slapped on some paint.




heres the wrench that i used to bend the rods on the guard after the torch ran out of gas



paint!



 

4.0B2

Well-Known Member
Supporting Member
TRS Banner 2012-2015
Joined
Sep 24, 2009
Messages
10,700
Reaction score
150
Points
63
Location
Walls, MS
Vehicle Year
1988
Make / Model
Ford
Engine Size
4.0 v6
Transmission
Automatic
paint either the guard or the cover a different color.. make it stand out.. i vote the guard should be orange! lol
 

Surrey

New Member
Joined
Jan 12, 2011
Messages
1,800
Reaction score
9
Points
0
Location
Vancouver, Canada
Vehicle Year
1989
Make / Model
Ford
Engine Size
2.9
Transmission
Automatic
That is simply gorgeous.
Very nice work.
I need to make one for my lol7.5" once I get a damn welder...
 

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
i was thinking blue cover with a black face and a yellow guard? i dont really know yet, maybe ill just stick to my original smiley and just add the guard?
 

CountryBoy78

New Member
U.S. Military - Veteran
Joined
Nov 1, 2009
Messages
164
Reaction score
1
Points
0
Location
Rice Lake,WI
Vehicle Year
1994
Make / Model
Ford
Engine Size
4.0L
Transmission
Automatic
Looks good gives me a idea when I want to fab up some armor for my ex.

Have you made any more tail light guards lately?
 

ForOffRoadDriving

New Member
Joined
Aug 10, 2007
Messages
2,715
Reaction score
18
Points
0
Location
HIGHLAND, MICHIGAN
Vehicle Year
1994
Make / Model
FORD
Engine Size
3.0L
Transmission
Manual
i bent up the driver side tail light guard perimeter yesterday, but its been raining too much for me to fit and finish them.
 

Sponsored Ad


Sponsored Ad

Top