Curious, if this Dana 60 (complete) were to be for a Mopar race car, would it be worth the cost to cut the housing down and get new axles or is there a better less expensive way ??
I narrow my own D60 housings. If you already have the proper equipment (or you can rent it) it's much cheaper. But you need to have the correct tools like a calibrated bandsaw, housing alignment tool, and a welder powerful enough to get solid penetration.
It's not rocket science. Don't let it intimidate you.
Edit: If you end up going this route, Cass (Dr. Diff) can order you custom axles at any length. Cass is a good dude and he hooks me up with 40 splines.
The Dana 60 that I built for my '66 came out of a '76 Ford 3/4 ton. These truck rears usually come with desirable gear ratios too - mine had 4.10's, so I stuck with them. It was just a matter of buying a powerlock differential, a couple housing ends, a set of Dutchman Axles, 1350 pinion yoke, rebuild kit, and new rear cover. All in, I probably had about $1000 in it if that. I was even able to sell the stock trac-lock that came in it.
I will say though, it's a lot more work building one vs buying one. Next time, I'll gladly spring for a new S60 from Dr. Diff.