TonyatAirRide
+1y
Dont want to step on Max's toes here but I will see if I can help you out a little....
Chevy Diff and welding.... chevrolet differentials also known as GM CORP axles 10 bolt, 12 bolt and 14 bolt, they all have a cast steel center section. Welding to cast steel is a highly specialized area and should ONLY be done by those who are certified to do that. And even in that case, I still wouldnt do it. The popular Ford 9" is an all steel housing like the EARLY gm's and can be welded on directly on the third member housing.
Tri-link bars and lengths.... It is kind of like Coronel Sanders secret recipe. Everybody has their own formula alot which of alot of the ones I have seen out there are nothing more than mearly a guess but in short, no your upper and lower bars do not need to be the same length. As far as the angle is concerned, there is actually a formula to use that will achieve a proper upper bar length and angle but we will be right back to the whole secret formula crap. What I can add though is that you have to make sure that you have enough angle on your upper bars in order to isolate lateral movement. I personally wouldnt consider going under 35 degrees.
bars / adjustable.... no they dont HAVE to be adjustable. In fact GM has been building non adjustable link bars for decades. In my opinion though, I would make one end adjustable. That way you have adjustment possibility (ie. pinion angle, alignment, axle center) after it is welded in. If you have a fixed bar guess what... you are stuck with what ya got!