Its not 100% complete so i'll up date once complete
THE DIFF>
I started with a 3.45:1 LSD 28 spline borgwarner that i removed from an Ford EF Fairmont Ghia, this diff is 1545mm from wheel mounting face to wheel mounting face
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010160.jpg?t=1270352130)
First thing was to strip the diff and remove the ford brackets
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010116-2.jpg?t=1270352397)
Once the housing was stripped it was time to figure out how much needed to be removed so it would fit the sigma right, the factory sigma diff is 1388mm wide but seeing as im using a ford wheel that has a +10 offset i couldnt go the same length as the sigma diff as it set the wheels out to far
I chose to go with a total width of 1355mm which meant i had to remove 190mm (95mm each side) from the ford housing this worked out to be a blessing in disguise as the ford axles differ in length by 95mm meaning I could use the short axle for the long side and have the long axle cut down 190mm splined and slotted in the short side
Before i cut the housing i scribed a line along the axle tube so a could re-align the ends in their correct position
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010122-1.jpg?t=1270353463)
THE JIG>
Once the housing was cut i needed a way to make sure it was going to be straight once welded back together, So i had a look on the net at how the pro's do it and found they use a housing bar, basically its a stiff bar that passes through collars that replace the bearings and in turn keeps the housing in line
Collars, the two larger collars go in the center the smaller fit in the axle tubes
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010117-2.jpg?t=1270353896)
Collars on bar
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010118-1.jpg?t=1270353968)
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010123-2.jpg?t=1270353997)
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010125-1.jpg?t=1270354105)
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010128.jpg?t=1270354140)
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/P1010126-1.jpg?t=1270354190)
A nice deep V ground into the join to provide a nice deep strong welded join, tacked in place with a mig all final welding will be done with a tig
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/SAM_0040.jpg?t=1270354431)
Cut and splined short side axle
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/SAM_0037.jpg?t=1270354367)
Diff dummy assembled to check measurements and to make sure it all works before final welding
![Image](http://i796.photobucket.com/albums/yy248/Gassed250_album/SAM_0039.jpg?t=1270354632)
Next thing to do is make another jig to help align the suspension arm mounts