First off READ THIS
http://www.torsen.com/fsae/fsaefaq.htm
Quote:
35. Are there other differentials, such as a Type 2 (T-2), available to FSAE teams?
At the present, the Type 1 University Special is the only differential and drawing that we can supply to FSAE teams. While this may change in the future, a team wishing to use a Type 2 must currently go to a junkyard or a car dealer’s parts counter. We cannot supply a drawing for any other differential other than the University Special.
If you choose to use a Type 2 then you will have to do all your own design work. Two good possible choices would be the Mazda Miata (1996 - current), or the Toyota RAV4/Lexus RX300 (rear only). Both of these applications are fairly compact (ring gear pitch diameter is less than 7 inches) and can be made quite light.
Advantages to using a Type 2 are: all machining work for the housing is single axis, simplifying housing construction, the gears require no timing to assemble, the unit can be put together quickly. If you are making your own housing, it can be made with no windows, simplifying sealing the unit from oil leakage. Also, Type 2 differentials can use almost any type of lubricating oil, including ATF. Another advantage of using a type 2 differential is lower cost in volume production. The Type 2 would cost $280 each for a run of 1000 units for either of the two mentioned above. Gear costs are $19 per side gear, and $9 per planet gear.
The drawback to the Type 2 is a lower torque bias ratio than the University Special. Adding clutch plates to the side gears can increase TBR. The TBR would then likely be higher than the University Special.
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Whats the reasoning to go with the T-2? ease of case design? it has a lower bias ratio than the T-1 and you cant get the prints for the T-2 (yet)
(I take it you have the FSAE special torsen unit..?)
For The FSAE cars the t-1 type has an excellent bias ratio in a lightweight package. If you create a custom housing you will have excellent strenght and will allow a reduciton in rotational inertia. If i were you, putting time and effort into redesign of the casing of the T-1 is probably the best idea.
If you are going to tackle "scaling" the T-2 to a fsae car size all i can say is ... good luck. You are taking on a very large project, gear profiles, heat treatments, material specs, etc... And in the end.. still have a lower bias ratio.
T-1
T-2
http://www.torsen.com/products/T-2.htm
T-2R
BTW... torsens site has lots of info. ].