How to Build a Simple MX5 Chain Drive Differential - No Machining, No Welding

How to build a cheap and easy Mazda MX5 based, chain drive differential using basic hand tools.
No lathe or welding required.
The video shows the conversion of the 1.6 and 1.8 Mazda MX5 (Miata), open action differentials from the NA & NB series cars (up to 2005).
The same build techniques can be applied to other differentials including some aftermarket limited-slip differentials (LSD) such as the Blackline HLF030 Mazda MX5 (NB), ATB LSD.

I used self-aligning bearings which combine the bearings with circular flanged, pressed steel housings SBPF207 for differentials with 35mm bearing spigots or SBPF208 for differentials with 40mm bearing spigots.

The output flanged, stub shafts come with the MX5 differentials. The ones on the 1.6L MX5 have (4)10mm bolts on a 100mm pcd for MX5 bolt-on CV joints.
1.6L open differentials use different output shafts from 1.6L VLSD LSDs (different splines and lengths).

The output flanges on the 1.8L (Torsen) MX5 have (4) 10mm bolts on a 110mm pcd for bolt-on MX5 CV joints.
Alternatively, 1.8L MX5 (up to 2005) can have conventional push-in type CV joints/axles rather than the less common flanged type output shafts. The 1.8L flanged output shafts can be replaced by the push-in type CV joints.

The sprockets are custom made and are available from https://www.bandcexpress.co.uk

The dimensions for the smaller 6" MX5 (1.6) differentials are: Centre hole 96mm diameter*, fixing hole PCD 114mm (8) holes 10.5mm diameter equispaced.
* Increase centre hole size if you are fitting the sprockets over the lubricant retaining can*
The dimensions for the larger 7" MX5 (1.8) differentials are: Centre hole 108mm diameter*, fixing hole PCD 134mm (10) holes 10.5mm diameter equispaced.
* Increase centre hole size if you are fitting the sprockets over the lubricant retaining can*

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