shortening a borg warner.

[briney]

Where could i find a pipe cutter big enough to do this? Ive got a B/W diff that will go into my car but couldnt seem to find a cutter big enough.

i bought one in gasweld for 50 bucks. the ridgid one i bought on us ebay about 5 years ago.

[Gassed250]

i dunno if a pipe cutter will get through them, bw axle tubes are about 6-8mm thick

[briney]

the vn one i cut today was 4mm at best. pipe cutter did it easy. so when everything is open tomorrow i'll see if i can get some solid and hollow bar to make up an aligning jig. thanks dude.

[briney]

lashed out today and bought 2m of 2 inch round bar. then a bit of hollow bar to make the other bits. the 2 inch round bar seems like massive overkill, but it was in stock and worked with the hollow bar in stock so i grabbed it. should see it monday. where is a good place to go in adelaide to get the axle shortened ?

[SR20 KE30]

Should have started with r31 skyline diff, more ideal length for what you are doing so pinion would end up more centre, 28 spline, same 4 stud as the front, same diff centre.

Once you weld it together you will still need to finish straighten the housing with heat of some kind. Strap some 2m long steel to axle bearing faces of housing to exaggerate any difference, and measure in between them to check for square.

[caged]

i cut one down, its easy as piss

its all in here
http://www.xfalcon.com/forums/index....age__hl__sigma

What size bar did you use, and is it just mild steel? did you just spin the spacers down out of alloy? Looks fucken great, might do a borgy for the express van.

[ALLMTR]

i cut one down, its easy as piss

its all in here
http://www.xfalcon.com/forums/index....age__hl__sigma

Said it before and will say it again, top job there

[briney]

Should have started with r31 skyline diff, more ideal length for what you are doing so pinion would end up more centre, 28 spline, same 4 stud as the front, same diff centre.

Once you weld it together you will still need to finish straighten the housing with heat of some kind. Strap some 2m long steel to axle bearing faces of housing to exaggerate any difference, and measure in between them to check for square.

i've bough the steel to make a setup like gassed250 used. if i cut the same amount out of each side of the housing, the pinion should still be in the centre ? yes, r31 would be easier, but there's none around here. i can get vn diffs for nothing.

this just in, the steel turned up today. i've got the first bit of hollow bar chucked in the lathe and have bored it. just got to knock the outside down now.

[SR20 KE30]

Yep true, just re-read the first post, axle difference of 100mm, cutting 100mm off each side.

From memory i thought the short axle needed extra shortening to be the correct length, but my memory failed.

[Momus]

Check and measure twice, (preferably by sitting the diff on the springs), for the pinion position in the tunnel and for the angle/tunnel vertical clearance.

Much grief to be avoided.

[briney]

Yep true, just re-read the first post, axle difference of 100mm, cutting 100mm off each side.

From memory i thought the short axle needed extra shortening to be the correct length, but my memory failed.

it's cool man. for a moment i thought i'd fucked up somewhere.

Check and measure twice, (preferably by sitting the diff on the springs), for the pinion position in the tunnel and for the angle/tunnel vertical clearance.

Much grief to be avoided.

thanks for that. i'd been thinking about how to do this bit. so you reckon get the diff sitting on the spring mounts, with the u bolts just firm then put the wheels on. then bounce the suspension and do some measurements ? 4 degrees down from vertical for pinion angle ?

[Gassed250]

What size bar did you use, and is it just mild steel? did you just spin the spacers down out of alloy? Looks fucken great, might do a borgy for the express van.

Its 40mm hollow bar the spacers are turned out of mild steel, i just took the bearing cups to a machine shop had them make them for me, i think they cost about $60

I didnt have to straighten my housing as it was within 1mm from end to end, i kept turning the bar as it was being welded to see if the tubes were being pulled around with the heat, if it got slightly tight we move to another spot and pull it the other way

The pinion angle was set while i was building the jig, I just bolted some angle iron to the sigma pinion flange and set it plumb with an angle finder, the angle iron just sat on the jig and propped the diff/pinion up at the right height, then i welded the suspension points to the jig

when it came time to weld the suspension brackets to the new housing i just bolted the angle iron to the pinion flange set it plumb with an angle finder, bolted the brackets to the jig and welded them on

Im not the sharpest tool in the shed and to tell the truth it was easier to do it than it is to explain lol

[briney]

so i've been back into the wagon lately. i have turned up the 2 adaptors that go inside where the carrier bearings go. next is the bits for the end of the axle. pics when something happens.

[ALLMTR]

Anyone know what a shop would charge to shorten a diff and a pair of axles?

[Gassed250]

Last one cost ma $800

sigma diff cost $320 including the jig and diff