Three things/angles to think about when assembling a front driven axle

1. Match the angles of the inner knuckles to each other, each wheel will have the same caster.
2. Figure and set the angle of the spring pads to the inner knuckles to achieve proper caster angle.
3. While at the same time setting the pinion angle (as it will be installed in the vehicle) in relation to the output shaft on the transfer case (they need to be parallel).

May want to approach them in a different order, and double check everything before committing to the setup.

It will also be important to lineup the tubes and the carrier so everything has the same centerline, will prevent binding of the moving parts.

Here's some info on setting up drivelines: http://www.stovebolt.com/techtips/driveline/setup/index.html

Before deciding to build your own axle at least have a look at what the professionals have to offer.
http://www.dynatrac.com/
http://www.solidaxle.com/
Pick up an issue of Peterson's 4wheel & off-road and check the ads for more sources http://www.4wheeloffroad.com
Here's an article (a very helpful one) from Peterson's comparing different custom axles/manufacturers

Grigg

•1951 GMC 250 in the Project Journals
•1948 Chevrolet 6400 - Detroit Diesel 4-53T - Roadranger 10 speed overdrive - 4 wheel disc brakes
•1952 Chevrolet 3800 pickup
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"First, get a clear notion of what you desire to accomplish, and then in all probability you will succeed in doing it..." -Henry Maudslay-