Update on the drive shaft I built using the 1 3/8 spline from surplus center. It failed after 3 trips. I twisted the splines enough to lock it up. I hit a rut and it jammed the d shaft through the transfer case.
I ended up buyng the Neapco parts that fabricator mentioned from drivetrain america to build a new one. I worked it out so I could reuse the end yokes I had. This one is 1 5/8, so it better last...