Not to throw cold water on your desire for an FZJ front axle, but have you considered going with a widened 60 series axle for the 9.5" diff, and just run 30 Spline Longs, knuckle ball gusseting, etc. so you can use your current Hi-Steer components? Of course, the plan will have to work for you, and if you have already broken mini-style Longs or anticipate doing so with 40s, then forget the idea, but I am more pulled in the direction of going with the 60 series front axle with the stronger 9.5" diff and keeping my Longs and MC 25mm Hi-Steer for a wider front axle. The big plus for my overall plan will be the disk/rotor FF rear axle with the 9.5" rear diff. With my 37s, I can't think this set up will be less than adequate, but I am sure to miss my HP 8" front diff.
Maybe in the future, I'd get the 80 series outers with whatever knuckle options that come out, but it's hard to wait. Shoot! Ruff Stuff still hasn't released his mini knuckle balls; eventhough, the release was projected for a year ago. I know it's not Dan's fault, but his delay seems to typify what happens with manufacturing timelines for aftermarket parts like this. I've got my fingers crossed for BillyBob13s knuckles of course.
Another option, which is also very expensive would be to run 9.5" diffs broached to 35 spline, while using the same drive flanges for the rear and custom 35 spline inner axles, and Dana 60 outers, such as SpyderTrax Pro Series 60 Knuckles for the front. Might as well go with 300M, too. I'd bet that Brian Ellinger could begin all of this for you next week. Can you tell that I am trying to be carefull with your money, too?
I have considered the option of fj60 front also. But I really want a HP front third and the bigger birfs. I think that the steering issue can be overcome with a bit of design and fab time. I have a lead on a pair of 80 series axles, so hopefully I will find out the price next week and see what I can put together.
