I charge $250 in labor to build a cast iron case and $300 to build an aluminum case. I insist on solid pinion spacers and FORD pinion seals. I do have the tools to spread the aluminum cases. Change all bearings and seals and measure pinion depth of OEM gears. I charge an additional $100 to set up non ford gears, IE motive,Richmond,etc. I refuse to mess with those cheap asian gears from ebay. They are absolute junk and will not operate quietly no matter how perfect the pattern.
Yeah, with a wife and 7 month old I can't use the kitchen. The wife gets mad cause I have laundry room, our closet, and the babies closet full of enough tools to stock a small garage. I've really been looking into doing it myself. I want my 4.10s back. And I prefer the cast iron, and shipping on that would be horrible.
Cast iron trac lok differential is about 100lbs the limit for ups to ship. Aluminum is about 90lbs.
Really that little of a difference? THe cast iron case felt a lot heavier than the aluminum. I know you are picky about those gears and I see why now cause if the depth measurement is some unknown number it makes it hell to get it right. My diff is still running nicely and quietly after a few thousand miles so I guess it was a fine build. I used yukon gears from a few years back before they went to crap and the rebuild kt from SCP.com.
To the OP the only other choice you have is to get a local trust worth shop do it. Im lucky I have one of the best local shops around that built mine. They are highly recommended for their quality work. With that said if the shop doesnt do this work on a regular basis then Id stay away from them. I read some bad stories about diffs being built wrong on here. Bottom line its not worth it to have it done twice.