Thread: A Salisbury with a Brazilian.....

Looks good Rick. I did the same to my IIA a long time ago, but since I just modified and strengthened the stock diff pan, it weeps a small amount of oil. The rockcrusher diff cover looks the goods.

your description of your IIa Sals on OL years ago inspired this one Ben. Also had a weeping modified stock cover and was going to make a plated one until I started to add up the time and things I'd have to get done by outside firms so just bought the Rockcrusher one and cut the bottom off it. Far better made than anything I could fab up, the gasket surface is ground, so will be leak free and as it is designed for a high pinion diff the fill plug is nice and high so I can easily add a bit of extra oil for the wheel bearings.

Where did you get the cover from?

How did you remove the excess metal from the housing???

Geezus Clarkie, dug this one up from the past

IIRC the cover came from ABT, it's obviously a Dana 60 one so the supplied bolts don't fit the Sals so I bought a few 12mm bolts a bit longer than the stockies as the flange is 8mm thick.
Had to cut a notch in the brake line bracket that bolts to the top of the diff.
The excess meat was taken off with a 4" angle grinder and a hack saw. Can't remember if I only used grinding discs or a cutting and grinding disc
A sawzall and an angle grinder to finish would be perfect and quick.

I cut the cover right up to the bottom of the lowest bolt hole, actually broke through the hole, that's how high I went and just filled the hole in the cover with Epox-o-leak
I filled the hole in the housing with a blind stud I made from a cut down bolt with a screw slot in it and either Loctite liquid metal or 262 so it wouldn't break through when bashing on rocks. The bottom of the threads were just exposed when I finished, and I wasn't game to go any further, but It'd probably be safe to do so.

The covers come totally bare and included all the machining debris, so I gave it a damn good wash in Drive and hot water and used a nylon stiff bristle brush, just like when you wash down an engine block after machine work, then a bit of rust converter on the outside then I just used Killrust flat black epoxy paint.

solid axle/diffs do dana 60 covers for about $160.
they will also machine the bottom of your diff gaining about 25 mm and a flat bottom.
the cover is very beef and definately helps replace strength lost with the machinihg.
you just take the whole housing in centre, axles and brakes complete. he bolts it onto the mill and machines away.
david

Here's a pic to replace the ones lost from the posts above when the image hosting company folded last November.

Rick, do you have a underneath / side view to see how much is ground off ??


How about this for some Dana 60 Bling for your Salisbury
ARB Differential Cover For Dana 60 Axles 0750001 | eBay



wonder if they sell them here as Salisbury Covers ?

They shore do I got one from arb in bendigo