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Billet front diff housing with stronger gears
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07-11-2016, 07:50 AM | #1 |
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Billet front diff housing with stronger gears
I'm researching to build a billet housing that will hold a stronger ring and pinion for the front diff. Space is pretty tight, but it looks feasible. Hoping to make a diff that could handle a 1000awhp car, with approx 30-40% going to the front. Most likely have a custom front driveshaft too.
My question to everyone here is what would people want in it for options? I was building the design around 3.08 gears for manuals, but also have 3.46 gears available for autos. Any other gear sizes that would be wanted? What about cooling, just some fins for air cooling, or would water passages to allow for coolant to flow through be ideal? Goal is to have as much diff fluid as possible, hoping a liter+. Thoughts? Who is interested in something like this? And what would be N acceptable price target? Just as a background for me, I'm a manufacturing engineer at a fairly largue company. Worked on performance cars for years, everything from total custom weird race cars, diff regearing, engine builds, turbo fabrication, etc. even built the turbo setup for my hayabusa but that was over tn years ago and my welding skills weren't great at the time lol. Last edited by reaper0995; 07-11-2016 at 09:46 AM.. |
07-11-2016, 02:32 PM | #6 |
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No plans on the transfer case itself, but I might try and play with the controller, actuator, override it entirely, or hope that another person solves that riddle! Not really sure what to do yet, but my first guess is to just unplug the unit and make a completely contained controller that has a toggle switch between 0/100, 20/80, 40/60, etc.
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07-11-2016, 06:13 PM | #7 |
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Here are some photos of the initial size I have to work with. It's tight,but it looks like I might be able to get some 7.2 inch diameter gears in there. The stock ones are just over 6 inches in diameter.
Have people had the spider gear carrier break? It would be ideal to not have to replace that, or at the least not have to make new spider gears... most likely replace gears first then go down the line of needed. |
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07-11-2016, 09:29 PM | #9 | |
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Looking at the unit I have, I'd guess that the bearings are not trapping the ring and pinion good enough and under high loads, or sudden hard launches, they get mis aligned and cause failure. Just a guess though. Also the one side is actually spring loaded! Albeit a pretty heavy duty spring washer, but thought that was interesting to float ball bearings for the diff alignment. |
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07-12-2016, 03:02 AM | #11 |
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The BMW front diffs are actually pretty stout. Just because a few people with almost double the power over stock, have shock broken them (wheel hop and abuse), doesn't mean they are shit. They are actually stronger and better designed than a GM 10-bolt from a RWD V8.
I'm in the 11's at the drag strip, and my 97K mile front diff will be fine.
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2011 335i X-drive 6AT / Pure turbo / 500AWHP/526TQ
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07-12-2016, 07:07 AM | #12 | |
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07-14-2016, 11:16 AM | #16 | ||
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07-14-2016, 02:17 PM | #17 | |
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I don't know how much this is going to cost yet, but it's looking like it will easily be over $1500, probably closer in the $2-3k range... But I'm trying to see what I can do to keep costs reasonable and have a solid product. Thankfully I know a lot about manufacturing and keeping costs low! As a point of reference though, the R35 GTR's have a billet housing for the front diff that is $3400, housing ONLY with no internals!!! I want to make a complete unit for sale, and be less than that... |
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08-28-2016, 01:31 PM | #22 | |
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Do you have any data to support this position? |
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