FWIW, we don't weld the spring perches back on the housing as those absolutely need to be done under the truck's weight. However the cut and turn is quite strait forward, customer measures their ideal pinion angle with a mocked up housing, we know the caster we like to use which gives a degree or so either way to nail the pinion and we do the knuckle rotation. We've cut/turned and shipped hundreds of axles this way over the last few decades. We keep a pretty good catalog of builds, engine/trans combos (thus front driveline length) here in a spreadsheet and can usually guess really close what angle is going to make the most sense for most builds. With the few degrees of caster allowance it's not proven to be an issue. That said, if one can do their own cut/turn, we fully support that... it's one of those jobs we do just to sell the knuckle and axle parts more than as a general service. Our jig and cutter make the process easier but it still gets our hands dirtier than we like
Shipping an axle across the US shouldn't cost more than $75-100 each way, less perhaps if you shop it around (Fed Ex Ground, Fastenal, etc). We do use UPS and we simply wrap the bar housing in cardboard (we don't need diffs, knuckles, etc) and then shrink wrap it... this is basically what we send back.
View attachment 1827243