Thanks for that Alex. I dont think we will be able to get photos of this casting process as it is all done in a bit of a hazardous environment and i cant imagine they would appreciate us being there to take photos. But Steve can no doubt explain the process if he has a moment.
The good news is that Steve and Tony visited the foundry today and they were very happy with his patterns and will do a cast shortly. Steve in the meantime will start on the next patterns.
Over the weekend they started reassembling the diff. The bearings went on beautifully (thanks Chris) as did the new coupling, after a little easing with a file. Once the worm shaft was back together, they tipped the differential housing on end and simply dropped the whole assembly into it. A bit of waggling and a final thump with the mallet and it was home. It is now all bolted up, turns freely and awaits the completion of the wheel assembly.