So I cracked the OD housing on my 06 4x4 cummins and have been thinking about using the the cracked one as a template and using billet aluminum or something stronger. What were some thouhts on this, and has anyone done this or something like it?

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So no one has any input? Good or bad.

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"Billet" just means a solid chunk, not any given type of aluminum. It would be crazy expensive to have one made up for you (I work in a prototype shop as a CNC machinist, so I do things like that all day...the prices are nuts). Do you have access to some good cad/cam software and a CNC, along with the skills to use them? If not, deep pockets needed.

 

you may laugh at this but first buff it up real good and spray it down with brake cleaner then try to fix it with JB weld or pigputty.........................the stuff is amazing I fixed a 241 DHD transfer case like this years ago and still no leaks

 

I have access to an airplane parts machinist who loves a challenge.

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