Personally, I really like the newer Polaris Ranger/RZR 800 front or rear axle and carriers. The rear carriers/knuckles are the aluminum ones similar to what Bullnerd has sketched. Fronts are a little different with the tie rod mount & all. Are the front knuckles steel or Al? Looks like cast/steel, so its already a basic tube with bearing in it. Weld on the link tabs.
Friggin' axles is as cheap as $70 shipped NEW. Would need to simply figure out what you could machine off the inner CV. The axles have the male spline, whereas if you made an adapter on FL350 trans output shaft, you'd want to machine off as much as you could from the Polaris axle inner, flush/center weld to the adapter, and be done. Just that you'd have to build an axle every time you broke one.
Take a FL350 or ATX hub and machine a recess cup for the freshly machined Ranger inner to rest/center. Weld it on a lathe with one end in the chuck and one in a tail stock (to center,
not to lathe-cut). Have your buddy turn the chuck super slow for you while you weld. Don't set the oil chip bed on fire! lol
New axles are $70 each. Carrier/knuckles are like $30 ea. $20/hub. CHEEEEEEEEEEEEEEEAP!
Anyone know the length on the front or rear axles? Angular travel? Looking at what kind of front suspension they're putting on these things, there should be plenty of travel (waaaay more than stock FL350). The 2015 Polaris Ranger has 9.6" front and 9" rear travel. RZR "S" and "4" have 12" front & rear travel. Stock Oddy (spec) is 4.3" front and 5.9" rear. From what I can find, the max angle of the stock RZR "S" cv is 27-deg (so...on a 15" shaft, max travel is ~15"). The aftermarket "Gorilla" axles have 40-deg travel, but are also $400+ each.
Lonestar sells extended axles, but you can back out the extra to get the stock length...
Measurements:
MTS +4 Axle Lengths
Front Axles = 20.175"
Rear Axles = 17.77"
XTR +8 Axle Lengths
Front Axles = 23.875"
Rear Axles = 21.50"
09-10 "S" Model Rear = 21.35"
11 "S" Model Rear = 21.75"
XTR +6 Axle Lengths
Front Axles = 22.375"
Rear Axles = 19.18"
09-10 "S" Model Rear = 19.18"
11 "S" Model Rear = 19.5"
09-14 RZR / RZR S axles are 26-spline outer and 27 spline inner.
Later model RGR/RZR use front wheel bearings 44x72x33.1 size, and rears are 40x74x40. So you can't put a rear axle in a front carrier, or the opposite.
This has consumed my lunch hour!