[ddmckee54]

OK, I have a mostly functional 3D printed Frankendiff. I modified the bearing pockets, as described above and that eliminated the booger caused by the bridging layer. Scaling the bearing pocket diameters to 3 decimal places instead of rounding them to 2 places seems to have cured the bearing fit problem in the diff housing.

I added a couple of fillets to the cut-out for the inner bearing in the pinion housing and printed it again - it didn't fit right. That was really no surprise since I couldn't get a good measurement of the depth to the inner bearing pocket. So I just guessed - I was about 0.75 mm too shallow. Well that didn't work as planned either, that extra 0.75 mm of cut depth managed to break through to the outside. When I fixed that, that fix broke almost ALL of the fillets to the rest of the housing.

By the time the shouting was over I had basically re-designed the entire diff. But it looks much prettier now, and the 3D model is a LOT simpler. Before it just looked, I don't know - chunky/clunky? It more closely resembles the Kong axle now, except that I can make a center axle out of mine by getting a replacement pinion and the bearings, and printing another pinion housing.