I try and stay on top of anything new that is axle related. It's sometimes tough because I can't see the entire market every day or how the products are ultimately used. Many months ago I saw what I thought was just plain overkill for most people (technically it still is) but I've been watching a lot of videos come out of Tennessee and other Southern areas where even modified, seemingly-bombproof Rockwell axles come apart under buggies with massive horsepower numbers and 44-inch tires. And I'm not just talking about a fragged U-Joints or a busted stock shaft. I'm talking about knuckles and spendy custom whiz-bang shafts. These guys are hard on axles. They appear to eat Dana 60s for lunch.
Anyway, the axles I saw were from Gearheart Engineering. They utilize a 2 1/2-ton Rockwell housing, third member, and wheel hubs that are mated to 5-ton Rockwell shafts, U-joints, steering knuckles, and spindles. The parts are crazy big and absolutely dwarf Dana 60 parts. The company also has some heavy-duty shafts and U-joints that are even bigger than the 5-ton parts. You can check 'em all out by CLICKING HERE.
The hot (lightweight!!??) setup appears to be to run steering 14-bolt axles front and rear with Dana 60 outers. And now at least one guy is stepping into 14-bolt axles with 2.5-ton knuckles. But if the 2.5-ton knuckles are already busting maybe we'll start seeing 14-bolts with these Gearheart 5-ton outers and shafts! Crazy times indeed.