Finally had a minute to pull some parts out of my R&D box and do some experimenting.
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On the topis the OE shaft with new flange, on the bottom is an OE outer shaft assembly for a hub-equipped vehicle along with an AISIN hub. Sure enough the correct hub pattern AISIN slips right on and the clips all line up. Win #1
The distance from the face of the CV to the drive flange matches the distance from the face of the CV to the AISIN hub on their respective flanges. Win #2
So, as long as the length of the actual inner axle is the same, we are good to go, bolt on conversion without event requiring mods to hub, spindle, etc. That would be win #3. I won't have time to do so before I head back to South America (driving Toyota's of course) so it will have to wait until I'm back in town later this fall. That said all of our measurements jive 100% so I think they will bolt right up. Kits will follow only after I have a chance to install personally.
Now, it would be
better if we can just get a gear made for the inside of the AISIN that accommodates the original CV outer AND has the correct snap ring spacing BUT that may require a pretty big buy-in and while we are selling tons of part-time kits for the 80, I'm not hearing much from 100 guys. Perhaps the lack of option is just well known and thus they don't call? The plus side of using the OEM outer joint assembly or a complete shaft is well, you get new parts. The complete shafts are good sellers and if you are buying those, the cost difference for the free-wheel hub variant is a near retail wash. Add the hubs and you're done!
This shows the difference in the stub length:
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