Has anybody tried changing the front differential to an '02-'05 expy/mounty IRS rear diff?
You know the one - the housing and cover are aluminum, and the cover is finned and heavy-duty, with built-in mounting points. It's designed to be solid-mounted,, and is very lightweight compared to iron housings.
But the important thing is that the whole unit is only about a foot wide- it's just a center section, without the tube & axle on the right side, so the CV axles would be longer, so the angles would be straighter, so you could have longer travel without hurting the CV's.
Yes, you'd need to make mounting brackets/adapters, but that could be combined with relocated LCA mounts.
The front spindles look like a good swap too - they're about 3" taller and use the same lower ball joint, so in theory you could do 3" of lift and still have stock UCA angles, or do 5" of lift and have the angle of a 2" lift... the upper ball joint stud is different, but that should be fixable.