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Boxing the diff on a 6

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Is there a way to reinforce the diff mounting bolts without removing the body?

I seem to remember reading about needing to cut the floor, but can't find where this was written. I *think* you can get it boxed in without too much trouble, but would rather do it all right the first time - I'm putting in an LSD and want to do it once...

Thanks in advance, Alan
/ubbthreads/images/graemlins/cheers.gif
 
You don't have to remove the body just the diff.
 
You can do it just by removing the diff and probably the rear section of the exhaust, but space is very limited under there and you'll be welding upside down. Some of your welds will be blind as well. It is not an easy job. I layed several wet towels on my chest to keep from setting myself on fire. It was no fun at all and I still got burned a good bit...mainly my hair.

If I had to do it again, I would remove the carpet from the shelf behind the seats and cut a U shaped section out of the sheet metal, fold it back and make my welds from the top. Once the welding is done, fold the sheet metal back down and weld it back like it was. Carpet will go back over the repaired area, so no one will be the wiser. Unless you're concerned with 100 point originality, this is the best method to make the repairs in my opinion.
 
Thanks - that was the eact piece of info I was referring to. As soon as I started reading I remembered it.

I'm possibly the worlds worse welder, so there is no way I'm tackling the job at home. Some jobs are better off left to the pros - regardless of the cost. I just wanted to give them some idea how to go about it...
 
I had a friend of mine come to my house to weld up my mounts. I had everything prepped for him. I had stripped all the paint off and cleaned them. It took him two hours and did an awesome job. Although it was a tight fit, the job was done with the body on.

You might be able to get a welder to do something off the clock at your home.
 
Hello,

Is there somewhere on the WWW that I can go to in order to learn more about this?

I too am very interested in beefing up the diff mounting, but wanted to understand what is involved and hopefully see some pictures of it if possible.

Cheers,

Jim.
 
Jim,
I had my diff mounts boxed as well as a number of other reinforcements completed while I had the body off the frame. The Roadster Factory published a three page article some time back regarding frame strengthening, I have a copy. Plus there is a word .doc floating around (I have a copy) that has a template for making the boxing plates. My frame guy used this and it was a piece of cake. I'll attach some photos of my frame repairs.
 

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Another photo of the diff bridge cross members I had my frame guy prepare. These are 1" stock which connect the diff mounting points and make the two bridges act more as one.
 

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Another photo of the gussets I had installed to the forward diff bridge, near the rear coil spring mounting.
 

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Finally, a photo of the steering rack reinforcement I had prepared during my frame-off. Basically 3/16's stock which links the steering rack to the front lower A-arm bracket.
 

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[ QUOTE ]
The Roadster Factory published a three page article some time back regarding frame strengthening, I have a copy. Plus there is a word .doc floating around (I have a copy) that has a template for making the boxing plates. My frame guy used this and it was a piece of cake. I'll attach some photos of my frame repairs.

[/ QUOTE ]

Hi,

The photos of frame reinforcements are excellent. Much better than found in some of the books about TR6 restorations!

Is there any way I could get copies of the two articles you mention?

The welding looks excellent on your frame.

One minor suggestion for anyone trying this type of repair at home for the first time. You might want to be careful to not overheat the frame by tack welding first in one area, then in another. Go back and fill in a little at a time, alternating areas to let each of them cool. A lot of concentrated heat from welding in one area can seriously warp a frame.
 
Alan, check your email. Just sent copies of article and template. Anyone else?
 
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