Bracing Hilux diff housings.

[ausyota]

I was thinking of adding some bracing to my front lux diff before I fit it and was wondering what peoples thoughts on it were.

Is the only place that its really necesary on the top and bottom of the swivel balls on the ends of the diff?
Really that is the weekest part of the diff right? and it is the bit that is ouside the springs so taking more load.
Is it a good idea to add any bracing to the rear diff?
How hard is it to weld on bracing without warping the diff housing?

While Im at it I will be shaving both diffs and adding some extra steel around the crownwheel part of the diffs as a bash plate.

Paul.

[MissDrew]

Mine bent on the long side, next to the centre.

[hypo]

get them check for straightness b4 u start coz its easier 2 straighten them b4 u brace them..

wen u weld braces on it just do small stich welds bout 20mm long in different spots all over tha place 2 stagger the point of heat so it wont bend, just take your time an do it bit by bit an u wont bend it........

an yes i braced the swivel balls and along the top and also on te top pn the outside of springs....

[4sum4]

When I did mine I didn`t tack the job anywere I done my first weld on the top part of the pumkin and let the Gusset bend up when it shrunk then cold bend it back down then welded the ends but not across only long ways and then back to the lower part of the pumkin then in the middle.I done a sh$t load of welding and it didn`t bend.
And shaving the housing is only worth it if the housing is tweaked

[rumble]

never had a front diff fail or bend-damaged rear ones though. Bracing is normally done across top on the long side. Later models diffs are stronger than the early ones. I shaved about 10mm off the bottom of mine-added a steel plate as well as front bash plate-havnt had a problem (yet)

[ausyota]

So what size and thickness RHS have people used as the long side top brace?
Paul.

[4sum4]

So what size and thickness RHS have people used as the long side top brace?
Paul.

2mm will do,I actually cut the bottom gusset of and put it on top and cut a peice of 82mmOD pipe in half and put it along the bottom on both sides all the way to the nuckles and welded were the factory welds on the housing are