I'm still toying with the idea of an OEM E-locker. I am quite familer with the modifcation/wiring/cable yada yada yada discusions, especially since I sold them for a while.

My idea is this, when drilling for the 2 longer studs, after your holes are drilled/threaded.. instead of welding a reinforcement flange, why can't you thread a longer bolt from inside the housing out. you could grind the head or use a low profile bolt that was threaded all the way to the head (no shoulder) to give clearance. this would be stonger than just a stud. am I clear or confusing you on this? I 'm curious to see if there is enough room to do this, I'm pretty sure there is since the only thing spinning outside of the carrier bearings is the axle shaft!

 

Sure, you could use the bolts instead of the studs. However the other purpose of the filled area is to make a sealing surface for the 3rd the sit on and keep gear oil leaking out. I suppose in place of welding, you could use a good epoxy to do the same, but you do need something there to tighten the 3rd flange down on to.

 

No need, I think you're trying to overengineer it.