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I've been building these for a while for my car community, but I just thought I'd throw up a pic of one that I just completed. Not totally finished yet, still needs holes drilled/tapped in the blocks on each side for load studs. Let me know what you think!
I wish those were MIG beads . I TIG those seams with a root and cap pass.
The gussets honestly probably aren't necessary especially considering that DOM is press fit into the flange. Those are 2 of the 3 mounting points for the entire differential and are threaded M14x1.5 when completed. The gussets may help but really I think they just make customers feel better.
This cover is for the 1995-99 AWD Eclipse/Talons. Above the ~600whp level they like to snap those two mounting posts off of the stock cast aluminum covers resulting in all sorts of bad things.