We aren't on the same page yet greenfield, what I suggested did not cause any alignment issues. The idea was to leave the old sprocket welded to the axle, cutting the outer part of it off so it is the same diameter as the differential. Bolt an extra plate to the side of it (using the existing differential bolts), on the inboard side (the opposite side to the differential). Bore out a new sprocket to differential diameter so it can sit exactly over the old sprocket, perfectly in line with it. Bolt the new, bored-out sprocket to the new plate, which is sitting on the inboard side of it (that is, with the hub of the old sprocket and the outside part of the new sprocket in line with each other, between the differential and the new plate).

[Linked Image]

Last edited by grumpy; 29/04/12 01:41 PM. Reason: Add sketch