Delrin Spur problem. ...Mike....
 

So I got my delrin spur today and during assembly, I could not get the gears to mesh in my slipperential properly. Upon further notice I realized my new delrin spur is thicker than my old steel one, thus causing the slipper to not mesh together properly...

So my question is, can I belt sand the non-pad side down to get it thinner? I attached a pic of the different thicknesses.

Thanks,
Ted
http://i255.photobucket.com/albums/h...g?t=1285287445

I think the delrin gears are mod .8 which is probably the difference

No, it's mod 1. It's the 46t.

The thickness of the plastic spur is clearly a couple cm wider (see pic) which means I cannot get a good mesh internally inside the slipper cup.

The way the unit is designed, a thicker gear should not be interfering with the mesh of the gears in the diff. The spur gear is entirely outside of the diff cup. If you are having mesh issues in the diff maybe there is a shim missing on one side or something... Did you assemble it with the pressure all the way loose?

Ah, I bet that's it!

I did not change the tension on the wave washers... I bet it it was all the way loose, then the side with the spur would get closer towards the diff cup to get the mesh right, then I would just re-tighten the slipper again. doh.

Thanks for the heads up.

The Delrin spurs are indeed wider in the tooth area for enhanced durability, but the wider tooth profile has ZERO impact on the slipper operation or fitment, or the internal gear mesh. When in doubt, dis-assembly and re-assembly is a ggod idea and a good opportunity to clean and replace the diff fluid if necessary as well. :)

The best way is to assemble the slipper side first, install the slipper/spur and tighten, then install the other side of the diff. That way you know the slipper side is properly aligned, and the other side of the diff isn't affected by the slipper tension so it's easy to screw on.

Yup, totally worked now. I just needed to loosen the collar on the wave springs. Cleaned up, and fresh diff fluid. Retightened the slipper and now she is whisper quiet.

Thanks for the advice guys.