Dana 30/44 hybrid! Opinions?

[Matt]

Here's the link for the article...link

I have most of the parts to do this, as I picked up a full-width Dana 44 Ford axle. I was thinking about just sending the current 44 shafts I have to be resplined and shortened to fit the HP 30 carrier, but I wasn't sure as to the difference in thickness of the shafts. I assume using a 44 shaft would be at least a slight improvement in strength over the 30 shaft , and I'd be going to a full-floater with the 1/2 ton spindles, hubs, rotors, etc.
It looks quite a bit cheaper than a 44 swap if you're not a master fabricator, as a chopped-down 44 housing would need LOTS of brackets welded on for CAs, coils, trackbar, etc.
What are some of the things I need to consider? I assume the HP Dana 30 would have plenty of strength in a full-float setup, particularly using 44 axle shafts. (IF this is possible)
Tell me what I'm missing...
TIA!

That article is Billavistas - and covers option #1

I did option #2

You can go one of two ways...

#1 use CJ inner "C's" and then use warn CJ shafts (297/760 joint) or have your 44's cut down and re-splined... The CJ inner "C's" will side on the OEM tube - then just follows Bill's article (funny how quickly he is forgotten around here!)

#2 My way: Use K-5 or other fullsize 44 inner "C's" with about 2" of tube attached - Bore out the tube left in the K-5 piece to slide on the OEM axle tube - you need to add 1.25" to each tube to use OEM XJ shafts (I used warn inners for an XJ and the warn outers for a 79' waggy (source of my spindles, hubs and brakes)

I also gusseted the top of the D30 tubes as they are pretty small - way #2 gives you some extra width and heavier inner "C's" to work with... - if you come up with any other questions just ask...

Matt aka wanderingwillys