I'll update the existing mods a bit later but I just bought this to build a custom from axle:
It's a high pinion D44 off a 1979 F250. Seems like the strongest factory casting, with more reinforcing ribs than the early 1960's and the late 1970's F150 versions.
Looks like tubes are cheap, so when more funds clear I will order tubes.
I can get S235 or S355 steel, varying thicknesses, from 3mm to 20mm wall. I thought about 8 or 10mm wall, for some HD applications Dana used 12.5mm. Any thoughts on thickness and S235 vs S355?