OK I bought a 14" cut off saw today. I got the inner axle cut (The three bolt plate cut off) no problem. The Hagen mod shows him pointing to the inner ridge on the cv but it looks like it is cut on the outer ridge? Which do I cut and whats the easiest way to jig this up and cut it? My cut off saw started to cut it but 1/2" down it just quit penetrating. Should this be cut with a band saw?

The axle steel is very hard, and the abrasive saws start cutting really
slow when the cut gets wide.

You need to make sure there is enough room for the diff mount bolts, I made up
one of these stub shafts and it was so tight we had to grind the bolt head down
so it didn't hit

Wild

I used countersunk bolts on mine to get around the clearence issue.

I got the axle cut and 3 bolt flange welded on. The bolts aren't going to hit, its close but they don't hit. Does this mean I left the stub too long?

In my opinion that's just right, good job

So I got my holes drilled for the widening. My new holes aren't spaced exactly the same on both sides. They are a good 1/8" off after I elongated the holes. What problems am I going to run into becaus of this?

Ok after a little more working I got the new A arms to line up. I measured from a solid point on the frame to the same spot on each A arm and it is the same 15 7/8". Is this critical or am I reading to far into this?

  That's fine, be critical, it's only your steering, handling, and highway manners that r involved.  No really, make it as good as you can, it helps with the alignment too when it comes time, your tech will have an easier time of it and will thank you for being precise.  and you will get it aligned right?

Yes I will be getting it aligned again. I finally had the chance to work on the Tracker this evening a couple hours. Got some cutting and welding done. Hopefully I will be getting the front end together this weekend. What size spacers has everyone used when widening??

I used a .5" spacer to make up the difference, then I went to a 1" spacer after modifiying my control arms. That's with Calmini coils.

Still slow going, too much other stuff going on. I'm to the tie rods now. I had to adjust them so far that there are only 6 threads left on the outer tie rod and 8 threads on the inner. What does everyone do about this? There doesn't seem to be enough threads left to hold it properly.

longer tie rod? longer adjusting sleeve? What did everyone else do?

Hmmmmm, I didn't need to do anything with mine. I did replace the ends before I took it in for alignment, but still used all the stock parts. Did you adjust both sides or just one? If you adjust from both sides you should have more than enough left. I've been running mine for 3 years with no issues.

I adjusted both sides. It just seems there isn't alot of threads left on the inner and the outer. I'll just try it and see what happens.

I cannot get the a-arm bolts(the ones that will move outward) out to move them I started soaking them with penetrating oil a few days ago. I can turn them with a socket and a breaker bar, but they will not come out. I've been pounding on them with a brass bar and hammer, but no luck. I'm afraid to use heat as to not damage the rubber bushings. How did you guys get thoes bolts out?