Sierra Front Differential Part III

The Sierra Front Differential is coming along slowly.

Ignore the sticky tape!

With the body of the sump cut away, some strength needs to be put back into the Sierra 4×4 Front Differential.

Hence the addition of the the 8mm thick 6082 Aluminium plate and the 3mm thick tubes.

The aluminium plate has yet to be cut down to size. (I’m awaiting blades for the band saw and I’m getting lazy in my old age.) But, Hopefully you’ll be able to see my intentions.

Another 8mm aluminium plate will be sandwiched between the bottom cover of the diff and welded at right angles to the one you see in the picture above.

Sierra Front Diff Plate - Sandwich Plate

You’ve probably seen thinner steel versions of what I’m on about on ebay. My advice is for less than £20 – buy one. It’s not much to spend to potentially save hours of work on your back, at the side of muddy road; just hoping you’ll be home for midnight. 

Sierra Cosworth Front Diff - Sandwich Plate

I still have a few other brackets to make. Particularly the one for the passenger side that mounts the whole thing to the chassis. You can see it in the CAD drawing below. I’ll also add a few triangulating corner brackets (they will probably be horrid dirt traps – but hey, that’s what jet washers are for!). With the diff’s casing urethane mounted to the chassis; both top and bottom; hopefully many of the weaknesses I’ve heard about should be taken care of.

Haynes Roadster 4x4 - Front Differential

There is a gallery of images here.

Once I have all these bits cut, it’s off the specialist aluminium TIG welders. I’ll be taking my MT75 at the same time.

Kit Car 4x4

I now have all the pieces cut ready to take to the specialist TIG welding company. It'll look much better once all the sticky tape is removed! There was a stage when I was worried that the assembly would be a little weak, yet this mock-up is roughly stuck together ...

Sierra Front Differential Part II

Sorry, but there is not much to show again this week. I ran out of welding wire and the reel I ordered on Fleabay still hasn't arrived. The same applies to the aluminium plate, aluminium tubes, gasket set and bolts. I'm rubbish at excuses when it cold........... What remains of ...

Kit Car 4wd Front Differential

Fitting the front diff has been one of the hardest parts of this build so far. The Rover V8 is not a huge engine but still finding room has been tricky. Changing the front timing chain cover has proved very successful. The differential has been angled forward by 5°. The Rover ...

Sierra 3.9:1 Front Differential

It's been a few weeks since my last blog and for good reason. My project has a new home. I had to knock down walls and do some pretty scary electrics, but the work is coming to an end. The next job is a heavy duty chassis table. More good ...

Modified Front Sierra Differential

Unlike the Rear Sierra Differential, the front differential is not located along the vehicles' centre-line. The prop-shaft driving the front diff exits the side of the MT75 gearbox and travels forward to the front differential bolted to the side of the sump. The front differential mounts only to the engine's ...

Front Axle Assembly

I'm not going to use the Cosworth sump, so I will need to replace this assembly. Normally the diff bolts directly to the side of the sump, however with this design the shaft that would run through the sump now runs in front of the engine. The front suspension axle ...

Sierra 4x4 Front Driveshaft Cover

This Sierra 4x4 Front Driveshaft Cover forms part of the Cosworth front axle assembly normally bolts to the nearside of the sump. In this design however, it will be mounted to a custom axle assembly. The cover would normally bolt to the right hand side of the sump / shaft assembly ...

Ford Sierra Front Stub Axle

I'm getting better at the CAD stuff. The latest item to get drawn up is the Sierra Group N front stub axles. When I started learning AutoCad this would have taken me days if not weeks to draw. These took about under an hour to measure up and they ...

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