Rear Diff Skid Plate? Yes! Mission Accomplished!

MSparks909 · Post by **MSparks909** » Tue Jun 19, 2012 9:57 pm

Ken G. wrote:
MSparks909 wrote:My buddy and I decided we are going to use 1/4" as well for the cover. We're essentially going to make a Carli style rear diff cover and incorporate the glide plate underneath the diff and attach it up near the pinion and have gussets inside the glide plate to sort of "fit" against the lines on the diff so that if a REALLY hard hit happens then the plate won't be smashed up into the diff because the gussets will prevent that. I will say that I'm not trying to compete with what you're doing Ken. I think it's great that you took the initiative to get the ball rolling as far as diff skid plates though. Mine will be a custom design, but can be easily duplicated if anyone on here likes the design/functionality of it.
No worries! I'm sure some folks will like what your buddy comes up with & some will like what Iron Pig comes up with. Free to choose as Free Americans (and our Canadian Power Wagon Bros)! My biggest hope is that it is strong, does what it needs to do, and is unconvoluted in design. It's got to be simple enough to where it isn't major butt pain to service the diff when needed.

This is very true. I just want to have a bombproof diff cover/skidplate that I can drag across the rocks at will without fear of breaking anything

. God bless Capitalism, eh?

GunniPWguy · Post by **GunniPWguy** » Tue Jun 19, 2012 9:59 pm

RustyPW · Post by **RustyPW** » Wed Jun 20, 2012 4:44 am

With the beating my rear diff housing has taken at Moab and Rausch Creek. I don't think it needs a skid plate to protect it. Just a good diff cover and something around the pinion seal area on it.

Powerwagonmark · Post by **Powerwagonmark** » Wed Jun 20, 2012 8:57 am

Ken G. · Post by **Ken G.** » Wed Jun 20, 2012 9:11 am

Well...I guess we'll see what Iron Pig comes up with....but I think the design will offer some protection to the pinion area, help the diff glide cleanly over obstacles, and even protect the diff cover by curving up slightly in the back. I can't think of much else I would want for rear diff protection. As soon as they do the prototype for me, I will certainly post pics. It'll then be sent off to be reverse engineered and laser cut for production.

Ken G. · Post by **Ken G.** » Wed Jun 20, 2012 10:00 am

Maybe something like this is closer to the mark?

But, I'm sure some folks would keep going until it's more like the second pic!

Post by **AceMan** » Wed Jun 20, 2012 11:06 am

The first picture is more what I was thinking. However, that second one is definitely more on the mark, especially on some of those Blue trails at Rausch!! And it will protect the trans and transfer case, which is something else our trucks lack.

I wonder what something like that would cost? The only drawback is when you have to work on something underneath. You have to take it off each time. Needs to be adapted if one has rock rails, too.

Ken G. · Post by **Ken G.** » Wed Jun 20, 2012 11:20 am

AceMan wrote:The first picture is more what I was thinking. However, that second one is definitely more on the mark, especially on some of those Blue trails at Rausch!! And it will protect the trans and transfer case, which is something else our trucks lack.

I wonder what something like that would cost? The only drawback is when you have to work on something underneath. You have to take it off each time. Needs to be adapted if one has rock rails, too.

I sent Cam at Iron Pig a copy of the first photo....he said they can definitely do that and he likes that design. I have to measure the diameter of the axle tubes and shoot that to him. I also told him that I would like to see the back part extended a bit and curved up slightly to protect the diff cover. As far as doing something like what is shown in the second photo.....Man! That would be pretty expensive! Plus, if you were to use heavy gauge steel front to rear, all of that would add a significant amount of weight. I had a similar (not THAT extensive) array of skid plates under my '79 CJ. They were built by Iron Pig, and had little doors and access points to service the drive train. It was nice, but it did add a good bit of weight to my Jeep. Do you happen to already know what the diameter of our axle tubes are?

TwinStick · Post by **TwinStick** » Thu Jun 21, 2012 1:35 am

I like that design too. I think our axles have 20-25lbs more steel in the pumkin area, than a reg 2500. But anyways, that first pic is what i invisioned, it would help to get over the rocks by being smooth/er & also protect the vulnerable pinion/u-joint/d-shaft area.

I'm all for pic #1.

If they could just extend it an inch more towards the rear, to cover the vulnerable diff cover lip, that would be GREAT !!!

Ken G. · Post by **Ken G.** » Thu Jun 21, 2012 9:56 am

TwinStick wrote:I like that design too. I think our axles have 20-25lbs more steel in the pumkin area, than a reg 2500. But anyways, that first pic is what i invisioned, it would help to get over the rocks by being smooth/er & also protect the vulnerable pinion/u-joint/d-shaft area. I'm all for pic #1. If they could just extend it an inch more towards the rear, to cover the vulnerable diff cover lip, that would be GREAT !!!

Yep...that's exactly what I relayed to Cam down at Iron Pig. It'll be extended a bit and slightly curved up to protect the diff cover. I also like the idea of using the big u-clamps, instead of using the diff cover bolts...that way the gasket and seal won't be in danger of being compromised. It'll also allow for easier servicing of the diff.

Can't wait until I get the prototype built and we get production models! Also getting them to build me some rock sliders....those will be outstanding!

FirerescuePW · Post by **FirerescuePW** » Thu Jun 21, 2012 10:20 am

I like it. The u-bolt idea is what I had in mind. I didn't want to use the cover bolts. If you drop hard onto the guard, you risk loosening cover bolts. If a u-bolt loosens it won't cause a leak. I think I may be in, too, depending on the time frame.

Sent from an undisclosed location.

Ken G. · Post by **Ken G.** » Thu Jun 21, 2012 10:34 am

FirerescuePW wrote:I like it. The u-bolt idea is what I had in mind. I didn't want to use the cover bolts. If you drop hard onto the guard, you risk loosening cover bolts. If a u-bolt loosens it won't cause a leak. I think I may be in, too, depending on the time frame.

Sent from an undisclosed location.

Yep....totally agree. If all goes right, we ought to have production models ready to go out the door by around the end of July (that's my estimate...maybe even a little sooner). The more folks who want in on a group buy, the less our individual costs will be, within reason. As soon as they build the prototype, I'll get pics of it and post them, so that everyone can see what the finished model would look like.

GunniPWguy · Post by **GunniPWguy** » Thu Jun 21, 2012 10:44 am

FirerescuePW wrote:I like it. The u-bolt idea is what I had in mind. I didn't want to use the cover bolts. If you drop hard onto the guard, you risk loosening cover bolts. If a u-bolt loosens it won't cause a leak. I think I may be in, too, depending on the time frame.

Sent from an undisclosed location.

Me too.

might as well have em for both front and rear that way IMO.

FirerescuePW · Post by **FirerescuePW** » Thu Jun 21, 2012 12:22 pm

I should probably say that I don't have a problem with the way the Carli cover is mounted because you usually hit going forward on the front diff. That shouldn't peel any cover bolts out. Dragging or dropping on the rear would stress the bolts in the wrong direction. I think.

Sent from an undisclosed location.

VA_Wagon Man · Post by **VA_Wagon Man** » Thu Jun 21, 2012 2:17 pm

FirerescuePW wrote:I should probably say that I don't have a problem with the way the Carli cover is mounted because you usually hit going forward on the front diff. That shouldn't peel any cover bolts out. Dragging or dropping on the rear would stress the bolts in the wrong direction. I think.

Sent from an undisclosed location.

Agreed.

MSparks909 · Post by **MSparks909** » Thu Jun 21, 2012 11:42 pm

Well I guess my prototype will be the guinea pig and determine how strong those rear diff cover bolts are

Our design incorporates the bottom half of the cover bolts, like the front Carli cover. It's also going to be attached to diff by the pinion with a u-bolt like some of the pictures Ken posted. I don't think using the bolts will be a problem, but time will tell when testing that's for sure.

RustyPW · Post by **RustyPW** » Fri Jun 22, 2012 12:43 am

If the skid plate is resting on the bottom of the housing, and the bolts are not susporting the weight. But just holding the skid plate in place. I don't think you would have a issue with the bolts.

MSparks909 · Post by **MSparks909** » Fri Jun 22, 2012 1:19 pm

RustyPW wrote:If the skid plate is resting on the bottom of the housing, and the bolts are not susporting the weight. But just holding the skid plate in place. I don't think you would have a issue with the bolts.

Hopefully not! That's how we have the design envisioned in our heads. I'm currently out of town but I know my buddy already started to mock up the design with cardboard on my old diff cover. Next step is sheetmetal and then we're going to get a 4'x8' sheet of 1/4" steel (HEAVY

) and cut out the plates and make the first "prototype". Once the actual rear cover is cut out and in place we're going to work on the skid assembly (it will all be welded as one piece when done).

Powerwagonmark · Post by **Powerwagonmark** » Tue Jun 26, 2012 12:18 am

Ken G. · Post by **Ken G.** » Tue Jun 26, 2012 7:11 am

Powerwagonmark wrote:

Hang in there! Turning my rig in to have the prototype built on the 16th of July....I'll post pics immediately following that, and I'll be looking to see how many folks want in on a group buy. Also getting my full-on sliders built, which will be mighty nice for future wheeling trips!

06powerwagon06 · Post by **06powerwagon06** » Tue Jun 26, 2012 7:31 am

Ken G. wrote:
Powerwagonmark wrote:
Hang in there! Turning my rig in to have the prototype built on the 16th of July....I'll post pics immediately following that, and I'll be looking to see how many folks want in on a group buy. Also getting my full-on sliders built, which will be mighty nice for future wheeling trips!

Now if we could just get you some sort of rock mover for the front of your truck Ken! lol

Ken G. · Post by **Ken G.** » Tue Jun 26, 2012 8:31 am

06powerwagon06 wrote:
Ken G. wrote:
Powerwagonmark wrote:
Hang in there! Turning my rig in to have the prototype built on the 16th of July....I'll post pics immediately following that, and I'll be looking to see how many folks want in on a group buy. Also getting my full-on sliders built, which will be mighty nice for future wheeling trips!

Now if we could just get you some sort of rock mover for the front of your truck Ken! lol

No Doubt!

Well....I'm working on some mods to the RH grille guard right now. I bought a wire feed welder at Harbor Freight that should do the trick for re-welding the steel straps that span from the front of it to underneath. I'm going to cut out the bottom tube, then cut wedge sections out of the grille guard uprights and bend the straps straight back and tuck them up higher to the undercarriage brackets. Also, I bought two skid plates meant for an XJ pre-runner bumper from Rusty's Off Road, that I will mount between the straps at an angle (pre-runner style). Finally, I have a stout piece of 2" tubing that will be welded in between the uprights at about license plate level. If it all goes properly, I will gain back the clearance that was lost from the original RH design, and also add protection to the steering linkage underneath the front end by virtue of the skid plates. I'll post pics of that mod, as well, in a different thread, once I dive into the mod full-on. I'll most likely need some suggestions if I run into any trouble. Wish me luck!

Post by **AceMan** » Tue Jun 26, 2012 9:37 am

That sounds! Like similar to what we've discussed at Rausch, and more.

Good luck! Looking forward to the pics!

Ken G. · Post by **Ken G.** » Thu Jul 19, 2012 8:48 pm

The new rear diff skid plate is on my truck!! It turned out great....can't wait to test it! Got my rock sliders, too. Iron Pig did a great job. Check out my post under the Member Builds section for info and photos. Plus, I'll need to get a list started to get numbers of how many :winchmob:

folks might want to get one of these rear diff skid plates. I'll test it out, then pull it off so that they can get laser cut production models made. We can do a group buy for $ savings, too. Iron Pig would be the first shop to produce rear diff protection expressly for our Power Wagons!

Post by **AceMan** » Fri Jul 20, 2012 2:44 am

You should also post it at DT for more exposure.

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