Ok so I did a bit more research today and one of my buddies at work pointed out something I had not thought of, the ABS ring. DOH>
So to answer all the 911 axle thoughts, no, they will not work. Mainly due to the ABS ring being in the wrong spot. If you don't care about ABS it may work, but i'll let you find that out.
So I tore apart one of my factory axles today and cleaned it up to see if I could use it as a 930 stub. For the record the CV that connects to the transmission is a 108mm joint, same as on the old 930 Turbos which is perfect because those are the joints I want to upgrade to!
The outer joint however is like 104mm and now I have to figure out a way to adapt a 108mm CV to it. I just went and looked and I think it would have to stay the same size until the end then have it flare out to 108mm in order to clear the wheel hubs. Next problem is a clearance issue with the sway bar link because the 930 joint would be so much further inboard then the stock joint. UGH.
I have a few ideas... The first and most expensive would be to have someone 3D scan the stub end, modify it accordingly then CNC it out~ That just sounds expensive. The second idea which my boss came up with is to slightly machine down the stub, then press a something like a 5mm collar that is 1/2" long onto the existing stub so it can be drilled and tapped out to accept 10mm axle bolts.
Once we have the stub in place the rest should be easy, just measuring and building the rest of the axle. heh. should be easy!
Here is what I'm working with, the 986 outer stub and a 930 cv joint cover:
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