Installing locking differential into truck and need to cut part of the diff to clear!

Grinder would be best to use

 

@Goodysnap is a very knowledgeable person in these parts. I wouldn't go talking to him like a butt head.

 

Its Ok, I can take it....

My point was that if he had mentioned he was converting from non locking to a locking the post would have made complete sense. Im not one for hacking stuff like that but , hey its not my truck.

Thats what I get for responding half awake that early in the morning.

 

Plasma torch and a steady hand.

 

That is probably great but I do not have ether. However I have done this job. Made a template off the new diff. Them marked the banjo with an engraver as best I recall. Cut what I could with a side grinder and 4" cut off wheel. Then went to a 3" wiz wheel. Probably blew out the corners with a torch. Finished it off with carbide bur bit a little at a time.
Do not start at the total amount you want to cut out. Leave some buffer room and work out to the finished pattern. It is a whole lot easier to go slow now than having to weld it up and start over. Not a lot of area to seal between the two housings on those so you need it all.

 

Ive done em with a death wheel and a cutting torch. Plasma would be king though.
If you install the locking diff without cutting a notch it stays locked all the time. Yeah..... one of the guys in our shop did it.