Okay.... if you're still having alignment problems then never mind. (But, how are you going to make sure a custom SAS is going to align right?)
My original thought was that you're throwing the baby out with the bathwater. Your problem is not necessarily the CVs but the misaligned used lift you had. You really confounded me in Moab - I've never seen someone blow a CV like you did (multiple times and all the breaks looked the same).
It's hard to describe, but your CVs looked like they sort of pulled apart rather than twist apart. You are the one and only person I've ever seen or heard of whose CVs broke like that. And when I saw you swap out your halfaxle, I knew something was wrong, because it was way too easy - you had just a fraction too much clearance to wiggle them in and out of place. When I've replaced mine it is an absolute bear to get them in and out and I have to have my steering turned just right to clear them. Of course later on you figured out what was wrong.
My "devils advocate" thought was that it would be a lot cheaper, quicker, and easier to get a new Superlift front and go with the CVs. You might break one every blue moon, but since you are not planning to take it on body-damage extreme trails, that may not happen at all. A lot of it is technique - don't hit the throttle when your steering is turned close to max and your wheel is at full droop (CV at maxed angle), and you won't break.
My only real CV break on the trail was on Steelbender and I had done exactly that. We were playing near the end of the trail and I decided to try to climb a vertical rock wall. My approach angle straight in caused me to hit my brushguard, so I angled into the wall at about a 15 ~ 20 degree approach, planted one tire on the wall, hit the gas while planning to straighten up, and with my front locker engaged I blew the CV when the other tire at full turn and droop planted on the wall while I was heavy on throttle trying to muscle up it. Stupid on my part. (I also had to replace one at the 10yr anniversary run in Indiana, but that was a result of rain, mud, and a split rubber boot that allowed all that $h!t into the CV).
That's it for me. I did the entire Rubicon which had gazillions upon gazillions of fairly tough obstacles without a hitch. Ray Lobato blew his CV on the Rubicon, but once again, he was between two trees on a ledge just past the Little Sluice when he fully turned his steering at the same time he dropped off, got full extension at full turn while he was hitting the gas, and kablooey.
I really think that if you take out the used/custom "almost-within-a-fraction-of-an-inch-but-not-quite-perfect" lift equation that you are running, you'll do fine. For a lot less expense and a lot less time and a lot less frustration than what you are looking at doing. Plus I know that you're considering the coilover conversion and I have to say I'm really satisfied with how mine is working out dumping the torsion bars.
But then again, SAS is always cool
