Second Bigfoot issue: I have seen where some people stick a BW1356 to a 205 as they have the same output shaft/input spline. This makes a giant long doubler. This is a great solution if you wheel a stretched limo.

The rest of the people I have found on the internet do some dumb ass thing where they cut the shaft, make an interference (force) fit, jam them together and then weld them, and then put them in liquid nitrogen, followed by pissing on them, like this guy:

http://pirate4x4.com/forum/showthrea...83#post6683383

Others talk about re-splining the shaft themselves. From what I understand this is a giant pain in the ass. Krebs kind of touched on it here in his Doubler thread, which is a good read because I threw in some classic Chuck Norris Jokes

http://www.tamor.org/forums/showthre...hlight=doubler

WTF? Moser will respline a shaft for $65.

http://www.moserengineering.com/Page...pservices.html

Look it up, Scott did it and wrote about it on this board. Why would you do an interference fit, etc... when for $65 it's done and done right? Does "cold machining" mess up the heat treat? Are these shafts just case hardened and not through hardened?