Weld in Differential Housing Bracing

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Luke
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Re: Weld in Differential Housing Bracing

Postby Luke » Tue Dec 24, 2019 5:41 pm

KevGoat wrote:Close to the truth there Bruce. I've had communications with 5 different parts suppliers in the US this year (nit just MX-5 btw) and 4 of those have refused to commence or continue communications due to my location - and reasons given were mostly due to past issues they've had caused by Australia Post!

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Yep.
Go back 5 years or so ago and it was easy dealing with US automotive part retailers.
Now most don't want to know you.

Unless it is something specific I need from the US that is only over there I tend to avoid it these days.

I used to buy almost everything for my MX-5's from the US before as it was far cheaper.
These days I find I am buying from Australia and surprisingly it is most often cheaper for non US made parts. US made parts can be cheaper but then you get smashed with shipping so it ends up being much the same as going to one of the official Australian resellers.



takai wrote:Use the other CAD: Cardboard Aided Design. Its not a complex plate, and even something bandsaw cut will be sufficient.


That I can do and I am considering it. I can give it ago when the housing comes out.
I could probably could get it to be just as good as the Miatacage one with a bit of time put into it as there's is realistically nothing special. It is just nicely cut aluminium.

The K-Miata looks very complex and far superior. There is no way you can make that by hand. That's what CNC and CAD does I guess.
If the cadrboard cut out is a failure I can always go up he road to Mania and buy these.
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Luke
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Re: Weld in Differential Housing Bracing

Postby Luke » Mon Jan 13, 2020 10:58 pm

As of today I have the diff housing out and a lot of other stuff.

It turns out I am changing my power plant frame as well as it has a crack in it. Already have a replacement.
The crack is in the 2nd last bottom mounting hole that has the spacer. When I took the bolt out the spacer fell straight out with the bolt which it should not do as it is a press fit.


I have started my CAD drawing for some aluminium diff housing braces.
First I applied black lithium grease to the diff housing section that I need to reinforce.
I then roughly cut some cardboard.
I pressed this piece of cardboard against the greasy diff housing.
And hey presto there is the shape I need to cut into the cardboard traced out in black grease.
Cut the cardboard to that shape and done.
I just need to get the correct thickness aluminium now. 4-5mm or 3/16in is probably about right.

The other problem is what type/grade of aluminium?
This will probably be important for welding. None of the American sites said what grade they used.
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Re: Weld in Differential Housing Bracing

Postby The American » Tue Jan 14, 2020 8:56 am

The spacer is meant to move down once the bolt is out - quite a pain when it is stiff.

FYI - my PPF cracked in the same spot.

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Re: Weld in Differential Housing Bracing

Postby Mr Morlock » Tue Jan 14, 2020 3:16 pm

there would have to be knowledge in your area on aluminium i.e. can you actually readily buy different grades. Also businesses that do welding will be able to offer advice. You can buy alu from Bunnings but I dont think there is any spec referred to. I have a guy in my area who specialises in Alum of all shapes and so any where in Capital city have specialists including welding fabrication etc.

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Re: Weld in Differential Housing Bracing

Postby Luke » Tue Jan 28, 2020 9:34 pm

It's done.
Image

Nicely welded by Grim Performance.
Very happy with the end result.
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Re: Weld in Differential Housing Bracing

Postby ralt » Wed Jan 29, 2020 6:14 am

Hi.
Well the performance has finally ended. Two pages of discussion to produce the finished product.

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Re: Weld in Differential Housing Bracing

Postby Luke » Wed Jan 29, 2020 1:01 pm

ralt wrote:Hi.
Well the performance has finally ended. Two pages of discussion to produce the finished product.


???
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Re: Weld in Differential Housing Bracing

Postby takai » Thu Jan 30, 2020 10:29 am

Luke wrote:
ralt wrote:Hi.
Well the performance has finally ended. Two pages of discussion to produce the finished product.


???

Salty ND driver?

CAD looked like it worked well. Did you use 4mm alu? I would think that 4043 would be fine for this type of job, and would make it easy with 4043 rods.

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Re: Weld in Differential Housing Bracing

Postby ManiacLachy » Thu Jan 30, 2020 10:57 am

Looks beefy and strong!

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Re: Weld in Differential Housing Bracing

Postby greenMachine » Thu Jan 30, 2020 1:01 pm

ManiacLachy wrote:Looks beefy and strong!


:BROADY:

Front and back, or only back?

:mrgreen:
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Re: Weld in Differential Housing Bracing

Postby Luke » Thu Jan 30, 2020 3:17 pm

takai wrote:
Luke wrote:
ralt wrote:Hi.
Well the performance has finally ended. Two pages of discussion to produce the finished product.


???

Salty ND driver?

CAD looked like it worked well. Did you use 4mm alu? I would think that 4043 would be fine for this type of job, and would make it easy with 4043 rods.


I had a ND once. :wink:

When I had a chat to the fabricator he said 5mm is the go.
He also picked the aluminium out in the end and cut it up as he wanted it to do it that way so it was all 100% correct.
I did not ask what he used.

I still have my cardboard cut-out through.

greenMachine wrote:
ManiacLachy wrote:Looks beefy and strong!


:BROADY:

Front and back, or only back?

:mrgreen:


Only went with the back.
From what little info I could find out there it seems the ones that get done front and back in the states are the ones that have already been broken.
Obviously front and back would be stronger but I think somehow that would be overkill especially since 5mm was used.

If you look at the top there are also 2 small bits up there as well. Basically mimicked the miata cage ones, then mirrored it to the left as well.
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Re: Weld in Differential Housing Bracing

Postby bruce » Thu Jan 30, 2020 3:33 pm

5mm is pretty darn beefy!


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