So I've gotta admit this is getting pretty interesting, especially with those new shafts. I've got a WJ low pinion D30 that I've stiffened the housing on, but haven't put any fancy guts in it because it's low pinion and 27 spline through and through. Building a JL/JT housing (and retubing/deleting the CAD) with nice shafts would be a perfect match to my 35 spline JK44 rear.
You can get a pair of new aftermarket aluminum JL outer knuckles on ebay for under $300 (depending on how much you trust them vs OEM), or Synergy iron knuckles for $400 per, and empty new aftermarket axle housings for $800. Granted you would still need wheel bearings and brakes, but at least around here used takeout JL front axles seem to start at like ~$1500 and only go up from there. So if the materials and manufacturing quality of these aftermarkets aren't awful, it might not be a big deal to skip the donor axle all together. Too bad they don't seem to sell the inner C's on their own though
The idea of the clamping friction of this style of stub shafts making them a bit stronger than a floating shaft is an interesting theory. If that friction does actually provide some torque transmitting, you could almost add some valve lapping compound between those faces to lock them together when the nut is torqued

(or would that actually work the opposite direction because less surface area being clamped due to grit?). Granted if there is any movement, that means wear because abrasives.