Man, I don't get it. Who out there is still breaking front diffs? There are several good ways to make these safe and sturdy. Are you talking the housings or the gears? I'm still runnin' an aluminum housing ( braced up well) with an air locker and have done plenty of stuff that should have broke an unbraced one.
i was done breaking front diffs as soon as i put a sammy axle under it. LOL!
before i went SAS i was running stock aluminum banjo which held up fine unless it got smashed on rocks. a simble skid plate solved that problem.
the chunk was from a sammy with a mount welded on
the carrier was a sammy bored out on the pass side to fit the CV
inside the carrier was a lock right which held up ok with a broken pin here or there.
after breaking a 22 spline shaft i went 26 then couldnt keep CVs in it.
at that point enough was enough and havent broke a single thing since the SAS and i have been beating it harder than ever.
Your probably right, I watch guys beat the crap outa their sammy's and think " no way I'm doing that! " Course, I have to drive mine home.