DIY Offroad Diff Covers...100% Scrap Steel! Ultimate Land Rover Discovery Build Episode 4.

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Differential covers are the unsung heroes of any build. You MUST have these for reliable off-road performance but you have options on how to get them. You can buy them from a multitude of different manufactures or you can build them. Buying a nice set of off-road diff guards is a great option, but this is a channel for builders!
In today's video I want to show you some simple tips to building your own diff covers and give you an idea of the work involved. This unit from Barnes 4WD is a great off the shelf option should you decide to save some time and buy one. Thank you for watching and enjoy the video!
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DISCLAIMER:
Due to factors out of the control of Dirt Lifestyle, we cannot guarantee against improper use or unauthorized modifications of this information. Dirt Lifestyle assumes no liability or responsibility for property damages or injury incurred as a result of any information contained in this video. Use this information at your own risk. Dirt Lifestyle recommends safe practices when working on vehicles and/or with tools seen in this video. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Dirt Lifestyle. Be safe!
#offroad #overland #welding
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6 апр 2020

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Комментарии : 306

@chuckmarquart 4 года назад

You always keep my attention span 100%

@DirtLifestyle 4 года назад

Good! I'm glad to hear it!

@SirEpsidufus 4 года назад

Yes for sure, not something many channels are able to do

@gibson5056 4 года назад

Nate’s next video “ so I just built a complete off-road rig from scrap pieces I had laying around the shop” ... lol love the videos man!

@DirtLifestyle 4 года назад

Lol it might happen one day 😂

@ericmillier6652 4 года назад

I’m always excited to see the way you do projects like this. I see the video title and think of the way I would tackle the project and sometimes we differ. And I learn! Fun little project. Keep the videos rolling!

@nathanrotar5012 4 года назад

Gail banks did a whole series on diff covers talking about fluid movement and work being caused by poor design.

@Wooskii1 4 года назад

I just saw ur comment after leaving one myself trying to say what you did LoL.

@nathanrotar5012 4 года назад

@@Wooskii1 it was a good educational series. And just so evey one knows Im not say the one in this video is of poor design, but to check out what they discovered in there tests at banks.

@Wooskii1 4 года назад

@@nathanrotar5012 I actually saw that. Like you said, it was very interesting. I just couldn't remember where I saw it. I'm gonna give it another watch now that you jogged my memory. Thanks!

@hondafreak8613 4 года назад

I was literally just about to comment and say that its very important to keep the rounded shape for fluid disputants to the wheel bearings. You could alway make small flutes is on inside of cover to flow the oil outward at the top of cover.

@Tellyfive 4 года назад

Awesome series and proof that we have been lied to for years.

4 года назад

Lots of guys just throw money at a build but the real talent is the man who makes parts for that build and they work.

@DirtLifestyle 4 года назад

Thanks brother 👊

@onetruebob_tj 4 года назад

Excellent work! I'm certain the Barnes team is impressed and flattered

@calvinkatelynnhardage8576 4 года назад

Your ability to think it, see it and build it amazes me and your fabrication skills are amazing! I’m hoping to start trying to fabricate in the near future.

@DirtLifestyle 4 года назад

Thanks man 👊

@dvonehrlich 4 года назад

I have none of the skills, tools, experience or practical knowledge to do this but I love it. Also I immediately thought about finding an air cooled motorcycle or airplane cylinder with cooling fins cutting it in half and using it as part of a diff cover for some crazy styling and maybe some cooling factor.

@OntarioFreshwaterFishing 4 года назад

I have to say, I've been watching you since you started at bleeping jeep. Since you left the quality of your videos has skyrocketed. Keep up the good work man. You are helping alot of us home fabricators

@dmwi1549 4 года назад

Great video Nate. And, darn it, you answered all my questions about capacity, etc before I could ask. One thing: just because you buy something doesn’t mean it will be trouble free. That’s where warranty comes in, which does you no good out on the trail. If you built it, you can probably fix it.

@bobjackson7516 4 года назад

NOTHING better than pride from DIY. Great video man. Thank you.

@michaelhalstead64 4 года назад

Nate, this is some dope content. I wasn't expecting to lie it so much because I have zero clue how to weld and fabricate. Super cool stuff!

@SirEpsidufus 4 года назад

Your videos are super inspiring as a beginner to offroading! Finishing up my first vehicle build ever, an 88 Comanche 97+ swapped, and I just keep watching your videos getting more and more inspiration to do really anything I can dream of. Thanks!

4 года назад

It's also much more satisfying when you make parts and they work correctly. You can also get jobs when people see how well your part works and they want one just like it.

@oleroy4749 4 года назад

Great video Nate. I really appreciate how at the end you talked about building verse buying, and the learning experience. Thank you.

@DirtLifestyle 4 года назад

Thanks for watching 👍

@DrHavok1 4 года назад

Damn nice been showing my son your stuff he wants to be a welder and he's liking watching your stuff like dad does

@DirtLifestyle 4 года назад

Awesome! Thank you and your son for watching 👍

@Rick-4552 4 года назад

It looks great I enjoy your videos and like that you made it instead of buying

@mazevx2451 4 года назад

Do you ever thought about heat treatment? Even for mild steel it helps getting the structure relaxed and homogenous, better strength and so on. Just an idea... Great video as always!

@wvjeepguy8178 4 года назад

Diff covers like this are typically milled flat after welding. Also, for anyone watching this...not sure if he's sponsored by Barnes, but there are plenty of companies out there making strong diff covers for the Sterling axles.

@DirtLifestyle 4 года назад

Lol I couldn't make it more obvious that I am sponsored by barnes. I have coupon codes everywhere. But this video is about building things with your own two hands. Not barnes 👍

@chuckmarquart 4 года назад

Tough guys build their own shit

@Hickeyjones 4 года назад

They don't have to be milled. I didn't mill mine, and I used the same basic tools as Nate.

@wvjeepguy8178 4 года назад

No, they dont have to be milled, but fully welded versions from manufacturers usually are just as a quality assurance measure.

@vegasfordguy 4 года назад

Have you watched Gale Banks differential series? I know it's not the same thing as we're talking on road towing vs off roading. Still a great watch though! Awesome diff cover Nate, keep it up! Top notch all the way.

@DirtLifestyle 4 года назад

I haven't watched it yet but I've heard of it. Thanks man!

@phillipwells7162 4 года назад

Banks was for dodge ram

@vegasfordguy 4 года назад

@@phillipwells7162 Banks makes accessories for all 3 diesel platforms. I wasn't suggesting that Nate buy a differential cover from banks, but rather that it's a good watch in general.

@HomeWrenchin 4 года назад

When you just finished making a diff cover build video for your channel and then DirtLifeStyle releases one before you 😭 looks like a sick cover 👍

@DirtLifestyle 4 года назад

Lol thanks brother. I would never do that intentionally 👍

@mikethrapp 4 года назад

Subbed your channel 👍 Will watch some of your vids later 😁

@jckdann7 4 года назад

I subbed too, never to many videos now days.

@HomeWrenchin 4 года назад

Lol quarantine life has everyone looking at new channels. Thank you guys for checking it out!

@ati573 4 года назад

Wow, that's some real skills

@thechrisnels9955 3 года назад

I love the "I was completely winging it" words to live by

@TrashPandaGarage 4 года назад

Coolest fab video I've seen on YT in a while. Nice job, Nate!

@DirtLifestyle 4 года назад

Thanks buddy 👊

@kcscustom9759 4 года назад

There’s a good reason other diff covers have more angles, specifically to the immediate left & right of the ring gear that is. Without those angles the carrier bearings and especially the axle bearings, don’t get as much fluid as they should. Now just to be clear I’m not trying to bash you in any way I think it’s awesome your fabing your own diff cover, I’m just trying to help you not make the same mistakes I did. I’ve actually been doing the same for a couple years now but unfortunately after I made my first couple I learned this stuff the hard way. My axle bearings went out about 5 months after I installed my first set of fabricated covers, first the rear axle then the front. So I just swapped them out thinking it was normal wear considering I hadn’t touched them in like 150k. But about 7 months later same thing again, rear axle bearings then front a few weeks later. At this point I was kind of skeptical, like did I just get cheap bearings or..? But if so would it really be all four a few weeks apart..? And after doing a little research and staring at my axle for a bit I started to suspect there was something wrong with my covers. So after finally doing a bunch of testing I came to the conclusion that it actually was my covers that caused my bearings to fail, very little fluid was even getting into the axle tubes never mind all the way to the bearings. And it was then throughout my testing that I realized just how important the design and clearances of the cover are. If you want to get a better idea of what is “good” and what is “bad” when it comes to diff covers, I’d recommend watching Gale Banks series on diff covers. He really goes into depth with this stuff and provides a ton of great info and real life demonstration!

@totilsom 3 года назад

exactly what i was thinking.. way too much restriction, fluid will not perform as it should

@J_bish87 4 года назад

Another sweet video, stoked to see the disco done up.

@drubradley8821 4 года назад

That came out really nice... well done Sir.

@Mickale-Moranis 4 года назад

Nice. Test for leaks, bolt it upside down to something flat, fill with water...look for leaks. If you prefer use plexiglass, seal cover to it, and add a little pressure with the water inside. Let it hold pressure for 5 mins. As for capacity, you could drill a 'full' hole in the cover as full is usually at the bottom of the axle tube (interior diameter). You fill from the stock fill hole on pinion snout, and when it seeps out the full hole in the cover, you are done. Most don't consider this even with a raised pinion when a non-stock housing is placed into a vehicle and potentially overfill. Overfilling too much matters. Overfilling little really doesn't unless you have to pull a shaft and that side is lower than the other side when you pull shaft. Fluid gets by the carrier bearing.

@mattbarrett41 4 года назад

The steel was free.........time isn’t free. You’re making it work by putting out excellent content.

@SWBCrawler 4 года назад

Eh, if he's enjoying building, then the "your time isnt free" argument loses some weight. Enjoyment pays you.

@mattbarrett41 4 года назад

SWBCrawler- valid. However, Nate has exceptional skills. The Capitalist in me always sees the $$$ value in expertise in any field. Exceptional people in any field deserve to get PAID (said with my best middle aged, white guy ghetto inflection).

@SWBCrawler 4 года назад

I mean... He is getting paid.. technically. ;). I'm not saying your point is invalid. Just that some of us do this for fun. And that is payment in itself. I could be consulting for hundreds per hour in my free time. Instead I run a RU-vid channel and tinker on jeeps. ;)

@mattbarrett41 4 года назад

SWBCrawler -I do get it. I moved from woodwork to steel with my first YJ and a 110 volt Lincoln welder. You’ve never seen so many turds bolted to Jeep in your life......and that old girl got a lot of respect. I still smile thinking about her. She eventually died.....I called her Patches because as a New England Jeep, there wasn’t a part that wasn’t patched somehow. I couldn’t keep her together anymore. I have a JKU now. I won’t bolt my own crap on her because my work is UGLY. That’s where talented craftsmen come in. Do I want another old Jeep to hack and mangle? Absolutely!

@ms.karihart2983 4 года назад

Man what an undertaking home built teaches you

@patterry7757 4 года назад

Nice Nate. Heat input causes warpage. The TIG process, when properly welded, has a much smaller heat affected zone.

@brianluck84 4 года назад

A nice bead of permatex will help with any mild warpage. The inside is a perfect project for learning to tig since no one will see your learning beads.

@brianmaynard7320 4 года назад

Looks pretty much identical to the store bought.. AWESOME skills my man!!

@DirtLifestyle 4 года назад

Thanks!

@StockyBaldman 4 года назад

I've wanted to do this for years, great channel

@forrestcary Год назад

Man, all your videos make me feel like I can build my whole Jeep.. and I don’t own a single piece of fabrication tools.. lol these videos are the best on RU-vid. Nice work Nate, cheers from Salem,OR just a state south of you.

@pnwfabulous3454 4 года назад

Nice job man! That is one thing I need to build. Hmmm. Good excuse to buy a mig welder to hahaha.

@Bikesands 3 года назад

That’s a nice project. I love to see the thought put into it before hand for the process to eliminate any issues that may arise.

@martinwyke 3 года назад

We've used pipe caps to replace the entire diff pan on Discoveries, works well.

@Jursaw 4 года назад

Really enjoy the way you shoot and edit your videos. Great music choice and volume is on point. Always nice to be able to say I made that part and this part on your own too

@philjulga2726 4 года назад

That's a sweet Milwaukee porta saw rig ya got ...

@stacyreid5077 4 года назад

I really like that shop and as far as the diff cover it looks great

@kevingray4996 4 года назад

Awesome job man another homerun.

@BigWheelFab 4 года назад

You could also use some pipe. Great job looks good.

@shaunadams3170 4 года назад

That's what I thought he was going to use around the ring gear

@2LEJTurbo 4 года назад

Did you notice the mill marks where they machined the cover flat?

@DirtLifestyle 4 года назад

Yes

@Bread996 4 года назад

2LEJTurbo that’s what RTV is for :)

@Fix_It_Again_Tony 4 года назад

They probably don't take as much care when welding because they are producing them for a profit. They can just flatten them afterwards.

@Hickeyjones 4 года назад

I built covers for both of my Dana 44's. I had some oil seepage from one spot on one cover. A little more weld fixed that. Both of mine came out flat enough to seal. I used a junk 44 housing and just bolted them down and went to town. I let them completely cool while bolted down to the housing.

@johnnybravo380 4 года назад

I love this channel so much. I really hope this full-time youtube thing works out for you. Awesome content and really great tips, keep it up.

@GrimResistance 4 года назад

If you watch any of the videos by Banks Power you can see why this style diff cover is superior to the regular boxy style. It really helps the diff fluid travel up over the ring gear.

@phillippearce9680 4 года назад

Exceptional work as always!👍

@oby-1607 4 года назад

Good work. Now to go and test this on some rocks.

@ArizonaJK 4 года назад

Keep it up! Makes my want my old Disco back. Great job!

@Trustyconsultinggroup 4 года назад

You are officially my fabrication hero

@DirtLifestyle 4 года назад

Lol thank you

@ProjectDanH 4 года назад

I watched this video while enjoying a delicious steak, When I finished both, the video was more satisfying. 🤣 🥩 💥

@DirtLifestyle 4 года назад

Lol thanks man

@mikethrapp 4 года назад

Haha. Im smoking steaks right now lol. West coast time its only 5:45 right now lol 😁

@ProjectDanH 4 года назад

@@mikethrapp lol stuck in NY... forever 😔

@dam1041960 4 года назад

You need to see banks videos on the dif covers. To understand its importance to know what to do. Very informative.

@kevinengland4675 4 года назад

Like it Nate 🤘 🇨🇦 gives me another option for diff covers to think about 🤔

@Rozza43 4 года назад

I love all of your videos man, thanks for all the fantastic info you give in every video. It seems there is not a project that you are not willing to tackle yourself, whether you have done it before or not. I grew up with my grandparents in a wood shop, there was nothing he could not build or fix...that is how i like to be as well, but sometimes I just do not have the tools needed for some projects.

@jried9378 4 года назад

I just bought the Dana 60 cover and 14bolt Shave cover from Barnes last week. Awesome Vid as usual

@terminatorx5836 4 года назад

Absolutely awesome bro. Very motivating for a guy that’s new to fabricating like myself. Dope music as also too. Great stuff Nate

@enriquemendoza8209 4 года назад

Well thought out design. I only have an arc welder. Tons of heat. Minimum experience. Practice, practice I guess. Great channel, greater videos.

@nicholasbaldwin1674 4 года назад

If you love welding but don't want to build the whole thing but want a cheaper diff cover ... check out DYIfabparts diff covers. They sell all the parts to weld one up for a specific diff.

@johnbishop1911 4 года назад

For the rounded parts, I would use a piece of .375 wall pipe. You just need to size it accordingly.

@rcmike09 4 года назад

That would be like a 15 or 20 in pipe

@johnbishop1911 4 года назад

@@rcmike09 If that's an 11 inch ring gear. A 12 3/4 OD pipe would be close.

@SNAGEMNTAG3M 4 года назад

That's cool I need to practice welding more and then build a set for a Dana 60 and 70u

@Ryan_1997 4 года назад

👍

@glen4130 4 года назад

Cool project! Keep the great videos coming.

@ronthoman7138 3 года назад

NICE WORK!!! As Always.......I Love the detail and content! Well Done.

@patrickgrahn2238 4 года назад

Nice work as usual.

@gdazey1 4 года назад

It actually looks like the one you built and bought, will keep the oil perfectly on the R&P instead of sitting at the bottom and getting splashed around.

@AndrewBrowner 4 года назад

well you fill it to a certain level not with a certain amount, the diffs are designed to be submerged a certain percent to get the appropriate lubrication but not create too much drag and heat from whipping through the oil, make the pan hold more or less just allows there to be more oil capacity and a greater time between fluid changes.. when you wheel thats not a concern as youre opening up the axle for some reason or another pretty frequently, idk how the shape of the hump where the ring sits affects things as the oil is suppose to be flung against that and land on the bearings and top of the ring gear but i really doubt itll be a problem unless you start towing heavy fast and far with the rig

@Wooskii1 4 года назад

@@AndrewBrowner Well said!

@berard01 4 года назад

Nice job!! Definitely stronger and beautiful.

@DirtLifestyle 4 года назад

Thanks buddy 👍

@theKMUPPETS 4 года назад

Great content as usual!

@michaeldose2041 4 года назад

There is nothing more frustrating than carefully welding everything and having a little pin hole leak. What I've done to combat this is, to take dish soap right out of the bottle (no water) and apply it to the weld in question maybe an inch or two at a time. Get a rubber tipped blow nozzle and push it right up to the seam on the other side and blast away. Repeat until you've covered the entire weld(s). Even tiny pin holes will yield a bubble this way. It's saved me a lot of re do's and oil. Cheap and easy insurance!

@satarbhatti759 4 года назад

So good bro good job

@Frimsure 4 года назад

that looks amazing man!!! pros to you

@jamesmurphy4736 4 года назад

As always, awesome video!

@erichughes9098 4 года назад

Another instructional video thank you😎

@brokenpoortradingco 4 года назад

I like it a lot I think I’ll make one for my 10.5

@django2467 4 года назад

Nice ! Cheers from Barbados 👊🏽

@chrispartaka9164 4 года назад

Love the content! Keep up the good work sir👌

@kevinthouvenell1750 4 года назад

Awesome that's looks great 👍 Nice and strong 💪

@cole33333333 4 года назад

Nice job looks good.

@Blast357 4 года назад

nice video as always! stay safe

@jl3g4cy34 4 года назад

Just passing on knowledge but if you need to flatten something out that maybe off by 1-5 thou but it is in fact off just get the flat side and rub it back and forth on some smoothish concrete then hit it with some thousand hit sand paper to smooth it out again. Worked like a dream for my oil pan

@matthewfox3760 4 года назад

Banks did a good series on diff covers if your interested in top performance

@jimgavin1799 4 года назад

Another awesome video!

@thegreaturimeshi7266 4 года назад

Hey man love the videos looking for a tj to start a crawl build your channel has inspired me to learn to weld and fabricate the mods ill use on it thanks forall tue hard work you put into these videos hope to see you out in Colorado some day !

@madgirl564 4 года назад

Love your work man! Really inspiring keep it up

@DirtLifestyle 4 года назад

Thanks!

@paulpetraitis2130 4 года назад

Work of art!

@maijhiselemani458 4 года назад

Amazing.... thanks Nate.

@mountainlessmtb9940 4 года назад

Nice work!🔥🔥👍

@4570levergun 4 года назад

Good stuff man.

@mikehoffman3690 4 года назад

Very nice part.

@genoory5090 2 года назад

Awesome build! Just put a gasket ring around it when mounting I and you'll be fine!🤙🏻

@constructiontech1970 4 года назад

Looks good Nate!

@DirtLifestyle 4 года назад

Thank you!

@ypop417 4 года назад

Nice Build Nate for the ring gear and carrier covers you could use pipe if you don't have a way to bend metal.

@DirtLifestyle 4 года назад

Thanks! Unfortunately the cost for pipe that size is astronomical. 12" schedule 40 black iron pipe isn't cheap and you would need to find a place that sells by the foot. 👍

@ypop417 4 года назад

@@DirtLifestyle sometimes you can get drops or scraps that size