I'm looking at throwing fullwidth axles under my toy but I don't want to run a stupid-heavy rock-anchor like a 14bolt or a D70 especially since I'm still squirle powered. What does it take to make a 9" and or a Dana 60 35 spline? I can find either rearends for cheap. What are your suggestions? Oh and I'm planning on running a D60 up front if I go full width so I'd be running 8 lug axles out back as well. Thanks for your help guys.

A D60 is a stupid heavy rock anchor for a toyota just as much as a 70 or 14bolt is but if you want full width its probably cheaper than a diamond and custom axles. Some rear 60's in vans came 35 spline but you would be fine with a 3o spline. To convert you just have to change the axles and the carrier/locker/whatever youre using. A nine inch you would have to do the same thing but I'm sure building a nine will cost you more. If you want it 8 lug just get a 60 rear that matches your front and start calling around to compare the price of a 30 or 35 spline locker and factor in that you need new shafts too

a stock 60 rear also needs the spindles bored out to accept the 35 spline shafts. If you can find a Dana 61, they dont nned boring, and have larger tubes. But any of the large rears will work. They all have their points.
I myself am doing 60 front 61 rear.

I have a 61 rear already has the big spindles, from factory for sale $100. You would just need shafts, internals and gears, swap to disc.

9" may be worth considering, except you mention plans of d60 up front. Benefits of the 9" is same strength, but more pumpkin clearence from ground. $.02
Campy

How much do the spindles need to be bored out? Do I use Dana 70 axles or custom and what disk brakes can I use after I do the conversion? Would I use a d60 kit or a d70? Thanks for the help, I know a bunch about toyota stuff but the dana axles are all new to me.

when you bore the spindles out they need to get bored to the dana 70 diamater, 1.63 i believe is what i had mine done to, and what billavista has measured on a 70 spindle in one of his articles. you can get cut to fit shafts, cut down 70 shafts if tehy dont neck down where you need them resplined, or have full on custom ones made. im running the yukon cut to fits. and boring the spindles wont affect what disc brake ser up you change to, just get or make the bracekts and run gm calipers and rotors.

I run a 60 rear, got the spindles bored out for $150 and am running 35 spline moser shafts.......

I was wondering about what it talkes to run 35 spline in a 9 also just for my own knowledge...........would you need a bigger case to house bigger bearings?? What else would you need?

A stock 9" carrier uses bores that are 3.0625". In order to run 35 spline shafts in a 9", you need a spool (or detroit or whatever) that is setup for 35 spline axles... and a 3rd member & bearing caps that are bored to 3.2500" to accept the larger bearings used on the 35 spline carrier. Then you need the larger carrier bearings themselves. Some companies make 35 spline spools that are designed to work in the stock 3.0625" 3rd member with special bearings... but I wouldn't recommend using them. If you run the aftermarket 3rd member with the larger bore... you can run 40 spline shafts as well. 40 spline shafts, when combined with a decent spool and a race gearset with a 35 spline pinion shaft & matching pinion support... make for a damn near unbreakable setup. Some of the really serious professional drag race stuff is setup to run a 3.8120" bore 3rd member.. but that's not something that's generally used in 4x4's.

Of course, if it's a front axle, you'll need to put together some kind of seal that rides on the inner axles to keep the gear oil in the center section, and if it's a semifloater rear you'll need bearings that fit the larger axleshafts and possibly new retainers on the end of the housing. Full floater rears will need drive flanges with 35 splines. That about covers it... the condensed version anyway.

What's ballpark cost on a set of aftermarket shafts for a 35 spline D60? I wouldn't need anything fancy, I don't even know if I'd bust the 30 spline but with big tires and low gears I'd want the insurance. Thanks!

a 35 spline 9 will take about 1k$.
buts its easy.
I would just get a 70 and shave it.

So it's as simple as getting a 35 spline carrier, boring out the spindles and getting 35 spline axles. Since search is down :( , anyone have picts or an example of what a shaved D70 looks like? Anyone have figures on how much Dana 60, Dana 70 and 14 bolt diffs hang down and how much you can shave off? I'm really leaning towards the dana axles or a 9" because I want to run really low gears like the 6.17's. That will keep the squirles happy running big tires and put a lot less stress on everything before the axles. :D

I got a set of 35 spline chromo shafts for my 60 for 200 even... FF shafts are going to be a little cheeper due to the lack of a bearing surface having to be ground on it.

why not take a 9" and make it a ff with 8 lug shafts? i dont know any other way youll get a 9" to 8 lug, the 14bolt is only 350# for a 1ton. i just picked mine up at the local metal yard and i had to weigh out and it came to ruffly 350. i would imagin a 3/4 would be lighter but i dont see any proiblems running a 350# rear in any rig. my one buddie is bitching at me tho cuz he says itll make me sink in the mud but once my rigs done ill be on nothing but rocks anyway.

Like I said, a ff60 rear end is still cheap, a lot lighter then a 14 bolt, uses nodular steel and offers better gearing choices. It will probably cost $500-$600 more to do the 60. If I wanted to do it really cheap and easy then I'd definetely use the 14 bolt but gearing and weight are more important to me with the setup I'm thinking of running. Anyone know how much a D60ff weighs??