Diff guards and corrosion.

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yup - and bigger oles means bigger bits of rock can hit the diff too. The water will do the damage too - coz it will stay in between the diff and the guard.
 
tbh a diff guard help's protect not completly protect's..

i have seen(only once thou) a mate's rr bob tail lose a diff with expencive guard's on and the rock never made it through but the intial tw@ting of the rock bent the guard and that in turn cracked the pan!

if it's gonna happen it's gonna happen ya can only try and stop damage not completly stop it..

your other idea was better having the diff pan strenthend daft mate
 
How about coating the pan in resin, fibreglass resin - that would bond well to any surface corrosion and give a chip and water resistant finish - it would also flow nicely into the pan/axle area. If yu is really flush, I suppose yo could layer up some carbon fibre over the pan to give added strength?
 
someone has suggested on another forum using a pipe cap as it makes the job so much quicker. See below. The cap is 9 - 10mm thick- sounds a good idea.

MVC-010L.jpg


here is the usual weld-in rear pan replacement.

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