I am getting ready to do the Rubicon again on memorial day. The last time I went with open diff's. I don't even have a limited slip.
Has anyone spooled a 35c rear with open front? I am thinking about welding it up and testing it out. Any imput would be appreciated. Troy in Tahoe

5" up, trimmed and plated.

Welding the 35c? IMO, you're just asking for trouble.. It wouldn't surprise me if you pulled out the driveway and made a tight turn onto Main Street to head down to the local store for beer and *snap* the wheel leaves the vehicle and ends up on the neighbors lawn. That diff is just too small...

Jay

I'll keep you posted so others can learn from my experiment. I have plenty of extra parts including replacement axles.

I have a few friends with spooled toyotas. They have tiny/weak pumpkins and 35 inch tires. So far they have had no problems.One of them is on his third season of off-roading. Troy in Tahoe

There was a great write up on welding/filling two valleys on each spider gear. By filling two of the grooves, it would prevent the open diff action, and allow the use of open diff action by replacing the welded spiders with good ones.

Search around on JU, and you might find it.

Here is my take on welding diffs.....if you weld the spiders to the side gears, and spiders and side gears to the case, it will be
strong as hell, and there will be no cross shaft interference.

When you do the welding, let me stress the importance of removing the carrier, DEGREASE
the snot out of it before you weld. If there is any contamination, like oil, you will cause
porosity in the welds, and it will be weak. Be sure to crank up the amps to get good
penetration. If a bead goes on and looks pretty, doesn't mean it's strong.

While the carrier is out, it would be wise to press on a new set of bearings due to the
extreme heat of the welds, and burnt oil in the bearings(you might get away with it if it is
antiseptically clean/degreased). If you do go for new bearings, the drawback is having to
reset the backlash.

Easier yet, why wouldn't a mini spool for a regular D44 work? For about $30-40, I would try
that first. If it diddn't work for some reason, it would be an easy sale.

For those who don't know. Mini spools replace the spider gears and connect the axle shafts
together, and uses the cross shaft to make it all work. Very similar to a "Lunchbox locker"
ie. Lock-Rite, EZ-locker etc, (but without the unlocking action).

Hell, if I had an AL44, and wasn't already locked, I'd try that first. You would still be able to
remove it and reinstall your spiders to regain an open diff if you ever chose to do so.

Oh, here's the link on the trick welded spiders http://www.customtruckshowcase.com/forum/showthread.php?s=a79df483daede6f1f4c2ede33665e43b&threadid=935

HTH
M.

Thanks I'll do a little research and let you know which direction I went. The cost factor alone is getting me excited. Troy in Tahoe

Finished welding it up today. I stayed away from welding the carrier to the housing. Metal types on the two were very different. Didn't feel it would be strong. Welded the spiders in 8 spots. Replaced fluids with synthetic and I'm off and running.

I'll run the Rubicon on memorial in two wheel drive and let all know how I did. Troy in Tahoe

I've been crawling three times now and the diff is holding up fine. I can do larger obstacles than before. I also have noticed more tire lift when twisted(Normally I couldn't lift tires this high). The locked rear is allowing greater performance. I can pull onto huge rocks with the front and slowly lift one rear tire several feet off the ground.

I also drive 30 miles strait up a windy mountain road to work each day. On road low speed turns are an experience. Tires chirp and bark. At highway speed I hardly notice any difference. I have to oversteer a little in the turns.

I've done two of my routine trails in two wheel drive. I never could have made it before unless I was in 4WD.

So for the best $35 I've ever spent Troy in Tahoe

Resist the urge to 4x4 with 2x4. The added stress and a D35 are asking for a broken shaft. The fronts (In 4x4) will help relieve stress on the rear, even if open, to some degree.

Let us know when it breaks. I liked the idea of welding the gear teeth rather than welding the gears to the carrier when I read it.

When my D44 front goes in, I'll add a mini spool or full, depending on price. I'm still up in the air on the 8.8.

M.