How to build a custom front dana 60 ?

[tylerdurden]

I have done numberous searches but can not find any good info about building a home built front axle. My superban project is going along slowly but surly.
I got a rear axle from a 02' 2500HD (single wheel). I say dana 60 but it is really a corporate 14 bolt axle, with 4:10s. I was thinking that if I could cut the axle tube on the passenger side down to 8 1/2" and then weld the remaining tube to the driver side. To make 27 1/2" with a collar to add more strength. I say this so as to stay with in buget. The only other questions are how do the inner seals work and do the tubes need to be lath down to fit the steering ends? I came across some artices about the tubes being lath down, but did not give spec. on size. The tubes on this axle are 3.5 inches and .470 thick wall ( if I remember correctly) Theres a whole kit on ORD website, without any pics. Any help would be appreiated.