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Interesting! Although it would be easy enough for me to turn down the seal surface I think those OEM stubs tend to be just surface hardened... so I am a little concerned they may break where the seal was. That seal is a brilliant find. Just need to open up the diff slightly. The Explorer seals...

Indeed I realize. Given the amount of info it seemed reasonable to keep it in this thread. The main contributor was active about 6 months ago (I did check before posting!). If no one chimes in I plan to get to the bottom of these questions and post the answers myself since the info is missing...

I am bumping this thread to ask a few questions! I am trying to replicate what you have done here. I am also trying to make custom beefy axles on a budget. Few seem to have tried this and there is little information online! Do you have measurements or specs of the Explorer "37 spline" CV axles...