I have a full floatr in my sammy it is a trail tough conversion with subaru callipers and uses an adaptor plate.
here is my trouble:   putting the weight so far out on the unit(length of: adaptor+samy spindel+2.5 backspace wheel)has caused an unusual strain on the chinsey bolt plate on the axel housing(my housing is the double tough  hybrid). the problem is that those plates have started to "tweak" causing the wheels to "toe out" almost making it look like a vw rear.
in turn you multiply that "tweak" back at the carrier and everything in my rear feels like it is bound. Dont get me wrong the setup I have is tough as hell but i really expect it to break and piss me off someday.the bennifits are good only in one case:if you break the shaft at the outer spline you can drive her home with minor work, if you break it at the inner spline you still have to get that peice out or you take the chance of dammaging your carrier. I dont want to say "dont do it "but i did have some experiences to share. my biggest suggestion to you is that if you decide to procede find a wheel(or have one made)that offsets the wheel in instead of out,with the width of the spindel on there now it will be wider than your existing front,and the offset  might? help the vulcrum position on the weight bearing on the axel.I will try to post some pics later.
jason

The thought was a 30 spline Toyota side
gear, and a 30 spline hub.

As far as the overall width, I seem to remember
it only being around 1/4" or so wider than the
stock rear width, if the mounting plates are a
problem either grade 8 bolts to prevent movement
or a thick backup plate to reinforce the thin housing
flange, or I have some other ideas too, thanks for
the heads up on this problem Locjaw

Wild

Look familiar ?



Anyone that's had their diff apart would recognize
this style of differential, Side gears anyone

Look familiar ?



Anyone that's had their diff apart would recognize
this style of differential, Side gears anyone

Uh yah,  

~Nate

Don't forget about the inner carrier.  The side gears will have to match the outter hubs.  If not nothing is gained.

Has anyone thought about a Scout rear D44?  I've been told there only an inch wider that our stock axils.  

I have 2 they are almost 8 inches wider than a sammy axle Wms to Wms but would be a good swap. I think the problem would be matching the front ratios.

Thanks
Wayne

I found a gear set for the D44(just looked up one of the popular supplyers) and found out you can get a 5.89:1 R&P.  

So for thouse of us running the 5.83's this would be a good match.  (it's less than 1% difference, so there is no problem.)

I found a gear set for the D44(just looked up one of the popular supplyers) and found out you can get a 5.89:1 R&P.  

So for thouse of us running the 5.83's this would be a good match.  (it's less than 1% difference, so there is no problem.)

Cool problem solved

Thanks
Wayne

There is a little play in the spindle
hole for a slightly bigger axle, all
outer half shaft stubs are 26 spline,
from what I have seen, so spindle hole
Dia. should be the same thru the years,
the inside shoulder of the spindle has a
brass bushing of a currently unknown
thickness, this bushing would not be
needed in a rear floater design, allowing
for a slightly larger axle to fit thru there,
hope being (crosses fingers) a 30 spline
for the rear axle shafts

Wild

This is question that needs answering. I think I remember an old post saying the Sammy spindle I.D. was 1.155" I've been talking to a guy today who can make new shafts with hobbed splines from N26 steel and then heat treated to toughen the splines. It's starting to look like Kick spindles with Toy lockouts that he modifys from 6bolt to 12 bolt so they don't loosen or shear and 27 spline sidegears for the ARB. This would result in an inner 27 spline of 29.5mm/1.16" O.D. and an outer 30 spline of 33mm/1.31" compared to the standard Kick 26 spline of 27.4mm/1.08". Not as good as 30 spline both ends but still better than stock and the sidegears are available and the lockouts are a bolt on I think???

The trick would be to get 27 sidegears
without the ARB attached

I've already got the ARB. Just trying to get confirmation on the sidegear swap.

Wild, as you'll see in my other post the 27 spline swap is out but a Dana 30 spline swap is available so 33.3mm/1.31" is possible at both ends. Need to know if this size shaft could be made to work with the axle housing and spindle.

The housing is plenty big for a 30
spline, (* edit: do you mean the carrier ?
I was thinking axle housing*)
I don't think it will fit thru the spindle if
it's close to the 30 spline Dia of a D44.

I think more along the lines of a 28
is going to fit, tho some machine work
could take some meat out of the spindle
hole for a little more room

Yep, we're talking D44 size shafts here   same size spline as the Toy shaft. It comes down to whether that shaft size can be made to fit.

Yep, we're talking D44 size shafts here   same size spline as the Toy shaft. It comes down to whether that shaft size can be made to fit.

I got one of each at home I will measure at lunch and let you know

Thanks
Wayne

I got one of each at home I will measure at lunch and let you know

Thanks
Wayne

Did you ever measure them?