|
|
|
|
Post Reply |
|
Thread Tools | Search this Thread |
02-13-2012, 10:51 PM | #1 |
Captain
194
Rep 933
Posts |
VAC Motorsports - 335i, 135i Performance Built Differential - How we do it!
Follow us on Facebook
Hey guys, A number of folks were wondering what our banner ad means when it says 'precision work done in house on our CNC machines.' I am proud to say that we in fact do everything in house - nothing is outsourced. As many know, most 335i and 135i models have a challenging stock differential. Unlike most cars, most 335i and 135i models have a differential where the ring gear is WELDED to the unit. Note: Just about every car on the road has a ring gear that is BOLTED to the unit. In order to add a Quaife, Wavetrac, OS Giken unit to your 335i or 135i, you need to re-use the ring gear and pinion in your differential. Not so easy since the ring gear is WELDED to the stock unit!! So, in order for us to upgrade to a Quaife, Wavetrac, OS Giken etc. we put our machines to work and created this incredibly accurate process to to separate the ring gear from the carrier and prepare said ring gear it to be bolted to the new aftermarket unit. This is a quick tutorial. We wanted to do the best job possible, so we configured our CNC lathes and mills to handle this challenging task. The end result is beautiful =) How is a VAC Performance Built Differential made (this is not a complete list, but most major operations are covered) 1. Photograph and inspect every differential for damage/missing parts etc. 2. Drain and inspect fluid looking for shavings or anything odd with the fluid. 3. Remove cover, inspect ring gear, confirm gear ratio. Pictured: The infamous welded ring gear. Note how it is actually welded to the carrier. 4. Test backlash before dissassembly. 5. Remove axle shafts, old side cover seals, snap rings. 6. Carefully remove the carrier. 7. Remove inner races from carrier. 8. Clean up the carrier, and prep for CNC operation. 9. Set up the carrier in our ultra rigid and precise CNC lathe. Pictured: Stock welded ring gear/carrier on one of our lathes. 10. Machine away weld that secures the ring gear to the carrier. This is an extremely robust weld. 11. Remove the resultant step (weld) so it is flat enough to machine. Pictured: stock ring gear separated from carrier. 12. Machine the ring gear flat (to ensure a precise mating surface for the new unit) Pictured: Separated ring gear | fully machined ring gear | drilled/tapped ring gear 13. Set up the newly finished ring gear on our CNC mill. Pictured: Machined ring gear on our HAAS 5 axis machine. 14. Machine the ring gear to make it compatible with the limited slip unit. Pictured: Completed ring gear still in the HAAS mill. Before: After: Note how we machine the entire face, not just the area where the LSD bolts. Our machining method ensures ideal accuracy and reliability. Not sure that anyone takes it this far. 15. Assemble the limited slip unit. 16. Pressure wash and paint the housing. 17. Soda blast and clean the differential. 18. Install bearings/snap rings. 19. Check pattern, install seals, gasket material and differential cover. Pictured: Checking the pattern on the newly assembled differential. 20. Tag and prepare for install/shipment. Pictured: VAC Performance Build Differential with optional Billet Differential Cover.
__________________
Brian Casella
Sales Representative, VAC Motorsports Office: 215.462.4666 | Fax: 215.462.4667 EXT 13 | Email: brian@vacmotorsports.com Last edited by Brian_VACsales; 02-15-2012 at 02:42 PM.. |
02-13-2012, 11:47 PM | #2 |
Second Lieutenant
70
Rep 218
Posts |
Do want... Would go perfect with my M3/Ground Control suspension, diff is my weakest link still. Whats something like this run? Can you change the gearing to offer better acceleration?
|
Appreciate
0
|
02-14-2012, 06:44 AM | #5 |
Colonel
105
Rep 2,696
Posts |
Beautiful. Need to win the lottery for one of these asap lol
__________________
Faster, faster, faster, until the thrill of speed overcomes the fear of death… – Hunter Thompson
|
Appreciate
0
|
02-14-2012, 05:33 PM | #9 |
Second Lieutenant
10
Rep 223
Posts |
I didn't think I wanted an LSD, but this has me drooling. Beautiful work, and seeing how easy it looks on the post, should be pretty cheap, right ?
__________________
'13 Miata Gt 6MT, '10 135i AW 'vert 6MT, PE and PPK1 sold. Sold '09 A4 Cabriolet, a couple of Miata's, 2005 Elise, 2004 S2000....
|
Appreciate
0
|
02-14-2012, 07:39 PM | #11 |
The Stig!
54
Rep 889
Posts
Drives: 2008 135i 6MT
Join Date: Sep 2011
Location: Tulsa, Ok
|
Please pm me price as well!
__________________
2008 135i - FBO + JB4 15ohm + Water Meth
|
Appreciate
0
|
02-15-2012, 02:45 PM | #12 |
Captain
194
Rep 933
Posts |
Thanks guys!
All PMs were replied to. Thanks for the interest.
__________________
Brian Casella
Sales Representative, VAC Motorsports Office: 215.462.4666 | Fax: 215.462.4667 EXT 13 | Email: brian@vacmotorsports.com |
Appreciate
0
|
02-15-2012, 03:59 PM | #14 |
Colonel
105
Rep 2,696
Posts |
They have a group buy going on right now for anybody interested.
__________________
Faster, faster, faster, until the thrill of speed overcomes the fear of death… – Hunter Thompson
|
Appreciate
0
|
02-15-2012, 09:18 PM | #15 |
The Fat Stig
11
Rep 274
Posts |
That sir, is some spectacular work.
__________________
|
Appreciate
0
|
02-15-2012, 09:54 PM | #16 |
Lieutenant
33
Rep 578
Posts |
If you join the group buy how soon do you have to send your diff in? how much does the entire thing weigh to get an idea for shipping costs across country.
|
Appreciate
0
|
Post Reply |
Bookmarks |
Tags |
differential, os giken, quaife, vac motorsports, wavetrac |
|
|