edited from my Nest posts
Here's the OE Eagle hub:
Flange diameter measures 5.70", hub pilot diameter measures about 3 5/8" and the knuckle steps down beyond that diameter to hold the inner seal. I'll get it bored out to 3.75" through.
Here's the 90-99 application Jeep unit bearing, TIMKEN Part # 513084:
Bolt Quantity=5 Flange Dia=6.043" Bolt Circle Dia=4.5" Bolt Size=1/220" Wheel Pilot Dia=2.812" Brake Pilot Dia=2.832" Flange Offset=2.133" Hub Pilot Dia=3.942" Splines=27
And here is the 84-89 application unit bearing, BCA/ Timken 513107
Hub Assembly; Front Wheel Bolt Quantity=5 Flange Dia=5.69" Bolt Circle Dia=4.5" Bolt Size=1/220 Wheel Pilot Dia=2.81" Brake Pilot Dia=2.83" Flange Offset=1.81" Hub Pilot Dia=3.75" Splines=27
The old style is much deeper, need to see how this will effect CV shaft depth and alignment, I may have to go for the newer style after all and figure out what to do for brake rotors
I've got a couple things to check before I pull the trigger on milling, I think. Still hoping to do it first thing tomorrow though.
Looking at the knuckle, I think I'll want to gusset the top where it necks down, going all the way through with that diameter will take away a lot of the material that holds the top to the body. The caliper bracket bridges the back side but I think I'd want to add some material back in for long term durability.