I just know your basic shadetree mechanic stuff along with some good electrical and radio info. I haven't worked on axle guts before. A buddy from my 4x4 club is going to be helping me out with this stuff and he's done this type of work many times before. I'm hoping to pick up a few things myself.
As far as the cost so far (S&H not included in prices):
HP Dana 60 and 10.25" axles: $1,250
leaf springs: $270 (shipping was a killer since they came from WA state)
Dana 60 R&P + full installation set: $300
Ford 10.25" R&P + full installation set: $300
Detroit Locker for the 10.25": $600
1410 U-joint pinion yoke for the 10.25": $210
The axle parts I got from Complete Offroad (
http://www.completeoffroad.com). They had better deals than anyone else I could find. S&H was only $11. I placed the order late last Thursday and it got to me the following Tuesday. Pretty good! Of course, they're in Iowa and I'm in Missouri! Still waiting to hear about why I don't have the pinion yoke yet.
I'm leaving the axles full width. I haven't measured them myself yet, but will post once I do. According to the Dana 60 Bible on Pirate, the Dana 60 I have is 69.25" WMS-WMS, about 10-11" wider than my current Dana 35 TTB. I'm sure the Sterling's about the same. I don't want to cut them down for two reasons:
1. Easier to get replacement axle shafts if needed. I know I might be able to but the long side of the 60 to some other shorter, stock length but I don't want to mess with it.
2. Wider = more stable.
I'll try to get some measurements this weekend. I'm getting excited!