I've been looking into the dana 44 up front for some time. Here's my $0.02.
Stay away form the Scout stuff. At first it seemed to be the easiest way to go. However, replacement parts are hard to find and expensive.You want the internal locking hubs. Much stronger than the bolt on type---no more loose bolts or stud kits. I found the convertion info for Dana 44 drum to disk at some Broncho sites http:// www.broncohq.com/rmtr-frontdiskconversion.html http:// http://www.bronco.com/tech/upgrades/...kes/index.html
Changing from 6 lug to five would be the same process. Just swap spindles out. You can start with a Jeep Wagoneer/Cherokee dana 44 or chevy/ford if you really want. I'd start with the jeep because you only have to shorten one side to get it to fit under a CJ widetrack. (see http://www.off-road.com/jeep/tech/cjaxleupgrade.htm
I stuck the spindles and rotors on the jeep Dana 44 and used the jeep brake calipers/caliper mounts. Jeep dana 44 brake hardware in the same as chevy 44. however jeep used a larger bearing in the front hubs. Chevy and Ford stayed with the smalller one thats why it all fits. Its all dana 44 stuff.
chevy spindles, junk yard, '74 pick-up $25
ford hub/rotors/bearings, '81 pick-up (f150 with twin-beam), junk yard $30
1 new ford rotor (couldn't turn one again), autozone, $40
Jeep wagie front end, complete, junkyard, $65
Cut/respline inner axle, moser, $50
Spring perches, confer, $20
Shorten Axle housing, ???,???, haven't got there yet but I plan on doing it myself.....
I know I should have got new bearings/seals, calipers and brake pads, but I wanted to see if it all went together first. A custom dana 44 for a CJ for less than $250 bucks! Dynatrac can bite me! Of course I could have spent the extra $100 and got the above mentioned new parts and I still need to change the gears. Call it $600, dynatrac can still bite me!
My name is Ted, and I'm a Jeep-a-holic.