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This one is kind of tough to guesstimate for me:
'72 F-100 with a non-GM engine that really cranks out some power(estimated 800 pounds of tork). How much power could a 9" take before I should consider a Dana 60 or 70? Even if equipped with Currie or Moser 35spl. shafts, a Detroit, and gusseting.
build it up and hope for the best. What kinda motor you got turning out 800ftlbs of torque. I would beef it up and run it. The trans, driveshaft and other components will need upgraded just as well but i'm sure you already know that.
A good aftermarket case, pinion support. (read Mark Williams) and 40 spline axles and you will never fail that 9". Dana axles are a pain to set up and they are not that much stronger. I had a trick Dana 60 that was built by Mark Williams with 40 spline axles in my *****'s Jeep and I blew the gears out of it a couple times with a small block. Of course a 40 pound flywheel and metalic clutch leaving at 8600+ on 20" paddle tires might have had something to do with it.