Chaz,
The shaft lengths are not the same on right & left. The CVs themselves (excluding shaft length) should be the same on either side.
When my CVs went bad, I could not find replacement half shafts and I couldn't find anyone to work on them either. I finally found an axle shop that agreed to work on it as long as they didn't have to pull the outer races (green cup) off the vehicle. They were able to do the job similar to what you described with the machining process & install bigger balls).
I'll see if I can find the thread about it. Joe Darlington's contact info is already posted there.
I've had a welder fab the drop brackets but I only have 2 spare diff brackets to work with. Both are still out. I don't know what Joe's current situation is with brackets for modification (he needs the originals back as well).
The only difference between what Joe sells & what I have done is that Joe provides a 1.5 inch drop & I went with a 2 inch drop.
Tom
BTW, here's the link to the thread that has Darlington's contact info:
http://www.vehicross.info/forums/sho...ight=diff+drop
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