Shawn:
Seems we've totally hijacked your post, but lots of good info so PM me with what you need,
Russ, yeah I have tons of free time...Ha But I had issues with my original design, although I have done two sets for other chassis and they work well, there was always a bug in my head about making changes as I had to clearance the upright for the CV joint and it never set well with me from a design standpoint. PM sent by the way.
Jac: I remember Bill E's posts and its hard to determine which upright he used, but there are also units used on the Mustang cobra which had an independent rear, and I have some of those half shafts and they are really substantial. The inner spline on the Cobra halfshaft is larger and has more splines than the T-Bird units, and they use different boots.
The outer CV and spline are the same, and I think the SUV's and Ford trucks are using the same outer CV joint....I am currently trying to source that info as it would make things much easier as far as parts availability.
I bought NOS Cobra halfshafts on EBAY for $75 ea. complete so the stuff is out there.
I can post some photos if needed.
Cheers
Phil