Ford 8.8 Differential Cover Restoration

As some may know, I'm in the process of restoring a 1991 Ford Mustang, and, since I'm trying to make some real power, it needs a 8.8 inch rear end to replace the stock 7.5 one. I was able to pick one up locally for around $200, but it was in need of a complete overhaul.
The first part of the restoration is this severely rusty and greasy differential cover. The process begins with removing the old gasket material and a thorough cleaning. Next, I removed the old paint, which was pretty difficult since the rust had almost melded with the paint. What I couldn't get off the wire wheel did.
The stock differential cover has no drain so over the years there were plenty of pry marks that needed to be straightened out. To make things easier in the future, and remove the need to pry on the cover, I welded on a small bung to drain the fluid.
After some sanding and final cleanup, I applied a high temperature primer from VHT and Wrinkle Plus, also from VHT. Everything turned out pretty well and I home everything else on the rear end goes as smooth. Stay tuned for a future complete Ford 8.8 differential restoration.
🎵 Track Info:
Title: Spaceship by jlsmrl
Genre and Mood: Pop + Funky

[@TheSchmed]

I would soak it in white vinegar overnight, then that rust just falls off. I’m doing my Jeep Wrangler covers next time I change my Diff fluid.

[@-DEATHSTROKE]

Highly recommended clear coat my bro, my wrinkle finish paint peeled off after a year

[@TheSchmed]

I would use engine paint on it.

[@anthonygonzalez364]

Use a plastic scraper the metal scraper can scratch the cover and cause a leak

[@Acaidia]

Nah using a plastic scraper would be inefficient because of how soft and unsharp it is. Especially if there's RTV in addition to the gasket. If you use a razor scraper properly you won't scratch the cover and even if you did scratch it, the scratch would be way too small to cause a leak. Plus it would only take 30 seconds with some sandpaper to remove such a small scratch anyway. You can use a razor scraper on glass so of course it's safe to use on metal.

[@TheSchmed]

Use a LubeLocker gasket when you put it back on.

[@thrRnz9496]

Nice job! Where did you pick up the drain plug? I'd like to do the same. What camera are you using also?

[@cannoncolossus2449]

Sorry for the slow reply. I don’t remember where I got the drain plug. They’re available everywhere in one shape or another, though. Just make sure the lip isn’t too big so it doesn’t interfere with anything. The camera I use is a Panasonic G85.

[@FamiliaMichoacana1]

What did you use to clean it before primer?

[@cannoncolossus2449]

I used acetone to remove all the oil.

[@802Garage]

Diff cover sized parts washer is cute. I need to get my big one going. Crazy how much rust was under the paint! Reminds me of my battery tray. You gotta get a powder coater next. Nice job. :)

[@cannoncolossus2449]

Yeah the rust and paint became one at some point. The parts washer is about all I can fit in my work, unfortunately. It makes it tough to clean larger parts for sure. I’m definitely getting powder coating equipment in the future. I need a sand blasting cabinet as well. There’s always something, lol.

[@802Garage]

Sand blasting cabinet is on my short list as well. Can never have enough tools!

[@Acaidia]

Same my battery tray was pretty rusty on my 95 F150 5.0. Good thing its made out of thick metal so it didn't really matter. It had some spots that were hard to hit with a wire wheel so instead of trying to remove every ounce of rust I just got 90% of it then used a rust converter primer. The only problem is that I didn't have a battery hold down for about a year afterwards and the battery constantly moving back and forth rubbed through the paint in some spots and those are starting to rust again lol.

[@keepondreaming3870]

Why do so much work and spend so much time, doing all this, when you could restore a used racing girdle cover for a deal. You still have same cover there besides drain plug. Next time use aerosol degreeser at Walmart let sit 15 mins agritate in, pressure wash off. Scrap silicone, use a angle grinder with buff pads on maiting surface and paint. I like the total restoration. I've would of cut out alot of steps and came up with same finished product in end. I'm not knocking you, just seem like alot of work for a $50 piece. I'm gonna be posting mine, that way. I can show you how it's done and make it Pop. I'm doing a stud girdle 8.8. Used to better than New ✅.

[@КошмарКошмар-й2б]

Hi bro 👋👋👋 very good restoration differential cover 👍👍👍🔥💣👌🏽