Here is a better picture of the finished productSomeone had a rear finned diff cover made?
Yes, I did consider a simpler geometry in order to make CNC work easier, but in the end there was no free lunch. Milling the fins would drastically increase the price. You want to cast as much as possible and have it on the CNC as little as possible to make it cheap. Just for extreme example: Milling this out of one alumium block would make the price go over 10,000 EUR for a one off. Extruding the fins forward of the mounting face drastically increases your surface area and cooling capacity. I leaned on AMG and M car design for the length of the fins. For a cheap production they are of course not ideal.It is absolutely a laudable effort. Considering https://www.bankspower.com/c-117-products-differential-covers.html runs into the $400 price point, I take back my quibble. Have you considered simplifying the casting significantly so there is a single flat reference plane, and using the mill to cut the external fins and detail work? Plus then you only need a 2.5 axis machine. I would also project fins under the cover but not forward of the mounting face.
What does your model predict as a BTU/h (or W/m-K) of heat shedding ability?
The other idea I had was to bolt a finned block to the outside edge and use thermal-pads-sheets at the mechanical interface.
Do you have a CAD (IGS?) of the Ford cover or a simplified view of your rough casting?
I think I'm going to take a bandsaw/mill to my spare cover and slap something like this on the back. Assuming it's compatible. https://performanceparts.ford.com/part/M-4033-KA
Edit: sigh S550 is 12-bolt cover, not 10.
No not yet. The first piece will go on a car in Germany in about 2 weeks. And a person in US will get it at the beginning of September who will test. I will report temperature numbers then. The cover was designed with exhaust CAD data as well and should have no more problem clearing it than the OEM cover. But the first installs will give final confirmation of this.@FluiX are you or someone running this?
Does it clear exhaust pipe?
What kind of temps are you seeing at the cover?
I think September is a little late but data is data.No not yet. The first piece will go on a car in Germany in about 2 weeks. And a person in US will get it at the beginning of September who will test. I will report temperature numbers then. The cover was designed with exhaust CAD data as well and should have no more problem clearing it than the OEM cover. But the first installs will give final confirmation of this.
Good point on the Torsen. None of EU cars have a Torsen from factory. But I am putting a Torsen in mine with a 4.09 final gear. The diff is already assembled and waiting to be put in. That will produce plenty of heat. So one piece for testing will also go in my car. But I will not have comparable before and after numbers because from factory the car has a 3.55 gear with clutch type LSD. The only thing I will be able to say is if it works enough to not go into reduced engine power mode.I think September is a little late but data is data.
I hope the German one has a Torsen as they tend to run hot.
Thanks
I am not quite sure which extra subframe portion you are speaking about. I don't know the extra reinforcements on the convertibles too well. Can you post a picture? Of course the part was designed more in mind for the PP and PP2 (Fastback) drivers who go to the track. But the external dimensions of the diff cover are identical to the OEM cover towards the rear and top of the car. It is only bigger due to the fins towards the bottom and the front of the car. Therefore, I think it will probably fit, but I could verify with a picture.And will it fit on a convertible that has the extra subframe?
thanks
CVCashmere
This is not a very high quality picture, but I guess it will do the job. As the bracket is only beyond the exhaust pipes I would guess, it should be fine....I think it will probably fit, but I could verify with a picture.