Seems to me that you are starting with the axle joints already angled some. That doesn't seem to be a good thing in my opinion. Starting with the axles shaft straight across, as when you use drop brackets, the joint has equal room either up or down. On that same subject, the reason I think you need longer shafts is not because of increased width, but because the shafts are angled. The reason there is a slip in there is because the axle needs to get longer as the knuckle drops. If you start out with the knuckle dropped, is there enough room in the slip?
Also, when you have lockers and are in bad country, you can find yourself with pretty much one single tire dilering all of the torque to the ground. Are those joints and the slip going to hold up with cut and turned beams?
I've nothing against exploring things and finding what works. Thing is, these axle pieces aren't being made anymore to my knowledge. You brake a shaft--it's gone. Most of the junkyard shafts are too whipped to trust. If you wheel a D35 TTB, you learn to take care of your stuff. I don't think you are going on Ebay and finding an axle shaft for a TTB D35.
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