Outer Limits 4x4 Board

I have a bare housing that I am going to reinforce before I install. I am thinking 10mm plate to gusset swivel balls and 2 inch box x 2.5 mm wall for axle tube to pumpkin truss. Any suggestions would be appreciated.

as far as the strenght goes the material you have listed sound suitable but its the method used in putting it on the diff that will get you into trouble, if your not carefull all you will have is a diff housing bent like a banana.If excessive heat is used and you dnt back step weld in short stiches a couple of inchs long then you will pull the housing. I suggest before you weld to the housing, build a jig so you know exaxctly how straight it was before you start because once its bent you dont really have a reference point unless you have another housing, then clamp it then put your braces on as slow as possible with suitable but minimal heat in the weld. If you do bend it and cant get it straight then throw a post up id be more then happy to share my methods as ive had a bit of practice lately Sorry if its slightly of topic but it will save a big headache. infact i bet that there is a fair majority of diff housing getting around that are bent and people dont even know it.

excellent advice. thanks. a description of how to build the jig would be handy. the existing diff i have is already bent. fairly sure the new one is OK.

Superior Engineering do full diff brace kits for these diffs.

Nice. I checked that out, it will save a lot of mucking around cutting it all to shape. cheers.

You dont really need a jig. All you have to do is weld the new housing to a thick steel bench in a few places and like they said only weld a few inches at a time.