From cast iron housings to aluminum

[geesamand]

I have a project where a customer is interested in using aluminum to build a differential housing instead of cast iron. All my past experience is in cast iron - as far as bearing fits, working stresses, machining, casting, etc.

The goal is to design a stronger/stiffer housing than the OEM cast iron unit. The aluminum option is intended to save weight.

What material should I consider for my aluminum casting? What is the most reasonable casting process for producing under 200 units? I intend to contact the bearing manufacturer for housing fit recommendations.

Any tips appreciated.

David

 

[Fabrico]

Ford 9"? You can buy reliable Ford 9" aluminum differentials off-the-shelf.

 

[pontiacjack]

Will this be to compete in the marketplace with products like Heidt's 9" Ford-based IRS?