We have built quite a few big front axles lately. So I have some info on what it takes to get it done.
When it comes to big axles we offer two options. 14 Bolts and Dana 80 s. I like both of them a lot. We all know the 14 bolt is a very strong axle but you can only go to 40 spline in a stock housing. With the Dana 80 you can get to 2" 47 spline. In the last year our industry has stepped up and made building these front axles so much easier. But here is a list of what I would recommend to some one building either axle.
40 Spline 14 Bolt
14 Bolt housing with new 3.5" x .500 wall DOM tubes pressed in
40 spline.com spool
Crane revolution Axle seals
For the outer wheel hubs you have two options
Ouverson Rockwell Spindles and hubs or Dana 60 wheel hubs and spindles. We have been going to the Rockwell hub and spindle lately because it is a little bit easier to deal with. The dana 60 wheel hubs require you to set the front race in then put a snap ring behind it. I have a hard time trusting the snap ring so I tack them in with a TIG welder. Either way works good though. Its really a personal preference thing.
If you go the Ouverson 8 lug hub route you get drive flanges with the hubs.
If you go the Dana 60 route then I would do a set of Crane 40 spline drive flanges.
2" 47 spline Dana 80
Dana 80 center section with either 4"x .250 wall or 4"x .500 wall DOM tubing
Crane Axle Spool
We build custom seal housings but I don't have any pictures to show.
Do Ouverson spindles and 8 lug Hubs for 2" 47 spline stuff
On knuckles with either axle I suggest our fabricated knuckles
We use RCV axle shafts mainly because of the turn around time and the warranty. You can't hardly beat them.
I know Ouverson will build custom axle shafts but I'm not sure on the price or lead time. I know if they come from Ouverson they will be quality though.
Like I said this is just the way I would put together a big axle. There are other ways to do it but these are two different paths to where all of the parts are available with little to no lead times.
We actually built a big press to help with re tubing axles in the shop.
We have a lot of experience in these types of axles and all of the parts are at our disposal. So give us a call if you need help .