Not sure how that would effect strength. It would have to go to a heat treater but i'm not sure how being previously treated would effect the process. Getting a whole gear machined would be the best but i'm sure that would start getting into high volumes of cubic dollars. LOL
It seems like you wouldn't have to worry about having that big of an axle on the inner sides like that with the portal box's outboard. I know bigger is better but with the reputation for strength that the 9" has I think my only worry would be if the hummer stuff was strong enough. I'd be talking to some military mechs to find out how things are holding up over there in the desert.
I have heard that they hold up real well. Plus they were designed for a HD millitary rig that was desighned for offroad.... And my rig probably weighs only half of what an h1 does. Staze works builds theirs with chromo shaft and the gear box takes off half the stress.... they say they have had no problems with their 44s on them on a fulsize truck. They run about 4 grand an axle loaded with chromo and lockers. Not too bad I dont think. Oh and they come with a shaved housing, and over 20in of clearance with 40in tires.
