I did a search and couldn't find the info, What hubs are you guys machining down to use for 5x5.5 D 60 rear full floater setups? I noticed that some Chevy hubs use a smaller hub dia than the rest. Are any hubs lighter or lend themselves better to the conversion? Would I be better off using 14 bolt hubs for the project?

yes

D60 front hubs seem to be easily machined down to 5 on 5.5. Could be fitted with either a locking hub or a drive flange. I asked last week if they fit on rear FF spindles, but didn't get an answer. Anybody know?

Are you trying to keep the stock axles? If yes, then I don't know. If no, then the Warn hubs are nice. If money is no object, call Sandy Cone or Summers Bros for their stuff.

I am starting with a clean sheet of paper and want to end up with a narrowed 60 FF with 5x5.5 35 spline shafts, and disc brakes. Looking to do it as cheaply as possible without ending up with a weak POS.

I'd look into the Warn stuff then. The price aint bad considering what you get.

Hint: Warn has a kit they sell to Currie minus axle shafts, then you buy axles from whoever you want in whatever length you want.