Thread: KAM diff lockers

For anyone interested in installing one of these lockers. I PM'd a NSW RTA approved engineer who posts on another forum.

His reply:

I wouldn't like to see it done without welding it. I'd be genuinely concerned about the strength of the housing.

Other than that, looks fine to me.

So it sounds like NSW people shouldn't have an issue getting the locker engineered - as long as the ring/flange is welded rather than bonded.

You may want to check in other states.

Originally Posted by Waxenwane

I have been following your thread on Megasquirt for some time now. .......................

Guilty as Charged

Megasquirt is prob one of the very best modifications I have ever done to my 90 V8, .......just don't get me started,.... 'cos you may find your will to live starts slipping away from you

I can now almost hypnotize a pub full of mates just by talking Megasquirt, and many other innocent bystaners close by - I see their eyes glaze over

Nige

Personally I would like to thank Nige for his replys. He has answered all your questions honestly and without troding on other locker manufactures toes.

We chose the KAM products to distribute because once Maxi Drive closed down we have not been happy with other locker products. We have been researching a replacement for the Maxi locker and used other products in the meantime and have been very disappointed.

Nige sent we a link to watch this topic. I have read all of the posts and the biggest issue is the cover ring, welding, glueing sticky tape etc etc.....

Test
We have just done a test, a crude test. We used an old diff housing and cut the tin cover off along with the section for the locking mech. As you would if fitting the KAM locker.

We welded the centre of the housing to the bench so each end was 2" off the bench. The diff housing is now only supported by a 50mm wide section across the middle where the diff centre bolts in. We welded to the bench a steel block at each end. We scribed the outer flange onto the secured block.

Now what we wanted to prove is how much an axle housing will warp if fully welded. We marked where the KAM ring would be welded as we would not be welding the KAM ring on as we do not have a spare and we believe the results would be worse without the extra support of the ring. We were crude, max amps. We welded a 2" bead. another 2" bead opposite the first. Than another and another etc. Always welding the next as far away from the last. Like you do when tensioning a cylinder head. We were crude because we did not allow any cooling time, we did not brace the diff in any way, we used max amps for max penetration and a full bead was applied. Once finished we let cool.

Once cool we scribed anothe line onto the welded blocks then removed the blocks off the work bench.

This is what we found. Long side raised by 1.3mm Short side 1.1mm. Alot less than what we were expecting.

Our conclusion is welding the KAM ring will not warp the housing much at all if welded correctly. That is a 2" weld followed by another 2" weld opposite the first and allow to cool 15 - 20 mins. Do this again and again until finished. It will take a while but you are reducing the amount of heat applied. With the KAM ring added and time to cool we can not see the housing twisting / warping at all.

If you are still doubtfull brace / preload the diff before welding but it should not be required.

Also spoke to our engineer about cutting the diff housing. Does not like glueing as posted elewhere but has no issues with welding. Actually believes to diff will be much stronger with the extra steel and the 6mm cast alloy cover. Much like the 130 defender rear diff with the extra ring added to increase the payload to 3050Kg's from 1200Kg's.

Hope this helps.

Andrew Richmond
Les Richmond automotive.

PS
If anybody wants to look at the KAM products you are welcome to drop in and look.