Need help designing diff cover.

[Anonymous]

Looking at making this diff cover. It is similar to the one in the picture. I am working in sheet metal because I want to cut the entire dome piece out on a cnc plasma cutter then bend it with my finger brake press.

The Issue i am having is filling in the gaps. I know they all need to be flanges so i can properly unfolt it, but can't get a flange to stretch the complex geometry.

Should I try designing this in another way such as in models?

[Anonymous]

The real part image you posted is 2 separate pieces of sheet metal and a separate blank for the drain plug.

There is a flange piece with the bolt holes, and then a folded piece that flares out around the diff.

[Anonymous]

I agree, but I am having trouble making the upper part that wraps around., not the flange.

[melvinbrian3d]

if you have the measures or share your .f3d file, upload here.

thanks!

[Anonymous]

I would be glad to! Hope you have a good solution!

[dwoodville]

I'm trying to do the same exact thing with a Ford 8.8 diff. Was there any solution to this as I'm stuck in the same spot. 

[etfrench]

Try it like this:

[dwoodville]

Yes that's what I ultimately am trying but it is rather difficult to acquire the angles and everything that is needed. 

[etfrench]

Start by making a solid model.  This will give you the necessary angles and sizes.

[dwoodville]

What tool would be best for a solid model? Lofting the corners doesn't seem to work. 

[etfrench]

Here's a crude screencast showing one way to do it.  Another way would be to use the loft tool.

[dwoodville]

Thank you for the video showing how you did things. I'm working on it and will report back if I can make things work.