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I think I've decided to make the pilot spacer and turn down the od of the flange. Hopefully, everything will work out and put the caliper and rotor in the same spot....

Trularin:
I haven't had to deal with any axle flange problems. I've had the axles bolted up with the caliper mounting bracket on and everything fits fine. Perhaps that's because the shop I had shorten the axle switched the flanges to the "big" ford style with the larger t-bolts to fit the end plate that the caliper mount bolts to.

750HP:
Are you sure the whole thing is case hardened? I would expect just the spline to be induction hardened - that's all that really needs to be hard. I kind of found the same "cold shoulder" when I tried to get Moser to tell me if the axle I'm looking for truly exists. "We'd be glad to make you a set for $295..."

Thanks for the feedback on Strange - they're a lot closer to home also. I think if my rework plan doesn't go right, I'll contact them.

If anyone does know of a 3.06 pilot dia, 6.25 OD, 31t spline axle shaft, let me know...