1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

DIY rear diff armor on the cheap

Discussion in '1st Gen. Tacomas (1995-2004)' started by paranoid56, Aug 18, 2014.

  1. Aug 18, 2014 at 12:12 PM
    #1
    paranoid56

    paranoid56 [OP] Well-Known Member

    Joined:
    Jul 25, 2012
    Member:
    #83443
    Messages:
    3,194
    Gender:
    Male
    San Diego
    Vehicle:
    14 double cab taco
    have done this on other toyotas so figured i would do it again.
    now you can go buy ones for 50-80 bucks and those are totally fine, but i like using these as they are beefy and cheap. just requires a little work.

    the main reason for doing this, is that the stock covers are paper thin, so a little ding on a rock will push it onto the ring gear. you dont want that.

    Step 1
    first up pick up yourself a butt weld 8" weld cap. they look like this. they are 3/8" thick. so very thick.
    photo%2B3_76baaa322b758c1b19fa7e47b98085c4b53474d7.jpg

    Step 2
    next up you will need to cut it in half. you can do this a few ways, but i used my band saw (you can use a chop saw, cut off wheel, hacksaw lol)
    photo%2B4_e79515aca9b6da245fbc4561b1cd232f6cc661b0.jpg
    photo%2B5_7cd068c2791c6b8c5bcbad9ecdabd1b66d0f8294.jpg

    Step 3
    drink a beer.

    Step 4
    once you have the two halfs, you will want to add a drain hole on the bottom. i also drilled and tapped a hole to reattach the ebrake cable guide. I also cut a half circle out of the top to get easier access to the fill plug. i did that with just a hole saw.
    photo%2B2_b146774cf3172b810de707662a8a996b81469fcc.jpg

    and a bottom shot showing the drain hole. i think i just drilled a 1/2" hole as that should be fine.
    photo%2B4_0c031cedf4f15e71f7c0a2b4da1de6d079f6b07e.jpg

    Step 5
    then weld it up. sand off any paint before welding and have at it. I will say that my bottom weld didnt turn out to great due to getting contaminated/ windy/ upside down lol
    but its not going anywhere. you dont need to fully weld it, i normally just do a 2" weld on both sides and one on the bottom.
    photo%2B5_6c391888a0d9662d2ab9fea725a04303d71efc23.jpg

    Step 6
    Drink another beer and watch the paint dry :D

    and one i did on my other toyota. this thing has hit many many rocks and still looks new.
    photo%2B2_2d5775d1f0e08fbe2dcdf9442ee10e2303329d2e.jpg
     
  2. Aug 18, 2014 at 12:23 PM
    #2
    Chopper678

    Chopper678 Professional Threadjacker

    Joined:
    Jun 13, 2011
    Member:
    #58237
    Messages:
    10,897
    Gender:
    Male
    First Name:
    Devin
    Texas
    Vehicle:
    '07 SR5 PreRunner V6 DCSB
    5100s@0.85"+Eibachs, Toytec 2" AAL, Weathertech floor liners, WO seat covers, UltraGauge, ammo box mod
    Nice writeup! I'd like to do this sometime just for the hell of it, I don't rock climb very much but this is nice to have no matter what
     
  3. Aug 18, 2014 at 12:26 PM
    #3
    yota243

    yota243 Well-Known Member

    Joined:
    Aug 22, 2012
    Member:
    #85267
    Messages:
    20,676
    Gender:
    Male
    First Name:
    E.J.
    north Alabama
    Vehicle:
    turbo 05 prerunner trd off road DC
    Bw s256 turbo with 3 in glass pack dumped pre axle raptor liner bed and top rails and fenderflares and rocker panels. Hunter side steps. Plasti-dipped upper fenders and emblems. satin black spray paint here and there inside and out. 5100's set to 1.75" up front . C channel front bumper. Maxxis bighorn 255/85/16
    looks good, no worries welding about getting too hot in the housing or anything? or did u do it with an empy rearend?
     
  4. Aug 18, 2014 at 12:29 PM
    #4
    Papa Taco

    Papa Taco HARD CAAAAAAARRRRRRRL

    Joined:
    Feb 20, 2013
    Member:
    #98004
    Messages:
    8,485
    Gender:
    Male
    First Name:
    Jared
    Safety Meeting
    Vehicle:
    2011 Access Cab 4x4 6 Speed
    Follow the yellow brick road
    awesome... just need a welder and some more beer
     
  5. Aug 18, 2014 at 12:30 PM
    #5
    paranoid56

    paranoid56 [OP] Well-Known Member

    Joined:
    Jul 25, 2012
    Member:
    #83443
    Messages:
    3,194
    Gender:
    Male
    San Diego
    Vehicle:
    14 double cab taco
    i normally dont empty the diff, but you can if you want. also, with small welds you are not putting to much heat into it. now dont go all crazy with it as you can put to much heat in it, but go easy with it and you will be fine. I also like leaving it full as having the fluid inside will help cool the welds faster.

    i also dont rock crawl with this, but i did it on my last truck before i got into crawling as i dented my diff cover when backing into a camping spot on a large rock at night lol. just easy protection.
     
  6. Aug 31, 2014 at 11:17 AM
    #6
    ckeene9

    ckeene9 Well-Known Member

    Joined:
    Sep 20, 2012
    Member:
    #87325
    Messages:
    10,868
    Gender:
    Male
    Chesterfield, VA
    Vehicle:
    '12 DCSB Supercharged 4x4 TRD Sport
    See Build Thread
    Great write-up! Now to find those caps... :cool:
     
    betterbuckleup likes this.

Products Discussed in

To Top