Pipe cap complete!

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So I managed to pick up a 10 in pipe cap for my diff. Got it from Ferguson plumbing supply.
Got it cut and installed today.
What I found was the fit was ALMOST perfect. I was a little deeper in its depth than I liked so it hung out in front of the housing by an inch and a quarter. After looking at it for a while, I opted to cut 3/4 off the back side to bring it in a lil closer to the housing. This allowed enough access down into the cover itself, but also didnt look so much like a SCOOP on the front.
I also added drain holes at the bottom, and cut some "swoops".
In hind site, I would probably had kept the "swoops" out and just left the material as half of the cap. I cut a bit too much off and though it will do the job, it wouldnt have been worse to leave it alone.
I found the best way to measure it, was to use a 90* ruler. Once I found a center line at the edge, its 5 and 3/8 in 90* incriments. So in other words, on oned edge of the ruler, you place 5 and 3/8's on the mark, then make another mark on the vertical edge at 5 and 3/8. Do this all the way around the circumfrence of the cap and you can bisect it in either direction.

Anyway, Here are the pics. I used an angel grinder for the straight line work, and my plasma for the "swoops" free hand. They may be a little un even, but...oh well.

Hope this helps!

Chicago
diffguard 001.webp
diffguard 003.webp
diffguard 004.webp
 
some more...drain holes (pilot bit, then a step drill bit to desired diameter), tacked in, stitch welds.
diffguard 005.webp
diffguard 012.webp
diffguard 009.webp
 
The finished product.:bounce::steer::bounce2::steer:

Chicago
diffguard 013.webp
diffguard 014.webp
 
Dang!!! nice work.

HMMMMMM more ideas to steal.
 
Dang!!! nice work.

HMMMMMM more ideas to steal.

Its CHEAP to boot...
Split the cost with a friend and its even cheaper.
I picked mine up for 48 bucks and some change, and a friend wanted the other half, so he ponied up half. 24 dollar piece of mind for all those pesky diff grabbin boulders trying to knock in your housing.

Chicago
 
Great. Dylan and I will get ours in short order. I want to use the plasma to cut it a bit closer to the diff. The one on my FJ40 has taken some abuse without complaint.
 
both are super cool
 
good ideas.... looks reasonably easy to do.
 
Hmmmm..... Very cool.

Chicago, why didn't you make the swoop cuts off center so the top portion was covering the ring gear?
 
pipe cap looks good, just need to fill your craters on your welds.

flat stock looks a little hack, but functional and that's all that matters

i'm noticing the stock diff gussets. i don't have them on my diff so i guess i need to make some.

good work guys

Craters are the drain holes.

Chicago
 
Hmmmm..... Very cool.

Chicago, why didn't you make the swoop cuts off center so the top portion was covering the ring gear?

That is kind of what I was saying about leaving the metal where it was. There was enough room to access the fill plug, but I just HAD to add some flare to it...Sooooo, I started and kept going, thinking..."this will look pretty cool IF....". It will work for what its supposed to do, but I could have saved some time and maintined some more protection.
I have OCD and really enjoy even porportions for some reason.

Chicago
 
That is kind of what I was saying about leaving the metal where it was. There was enough room to access the fill plug, but I just HAD to add some flare to it...Sooooo, I started and kept going, thinking..."this will look pretty cool IF....". It will work for what its supposed to do, but I could have saved some time and maintined some more protection.
I have OCD and really enjoy even porportions for some reason.

Chicago

lol


Good job amigo :)
Only thing I would say would be make the drin holes bigger.
It won't take much to clog those little ones up.
 
lol


Good job amigo :)
Only thing I would say would be make the drin holes bigger.
It won't take much to clog those little ones up.
We'll keep that in mind when we do mine with the other half. :grinpimp:
 
Here's a pic of the one I put on my FJ40-I want to make this new one exactly the same. Excuse the dirt.


attachment.php
 
If you mean the fill plug, then yes. That way WHEN you drop the fill plug, you don't loose it down inside the cap.

I have also heard of guys filling the void between the cap and the housing with exoxy to keep mud from getting in there.
 
If you mean the fill plug, then yes. That way WHEN you drop the fill plug, you don't loose it down inside the cap.

I have also heard of guys filling the void between the cap and the housing with exoxy to keep mud from getting in there.
Right, fill plug.

I'm not crazy about the epoxy idea, if any water did get in there it would be trapped.
 

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