Well, I lied when I said "good enough for Audi Expo". I though it was good to go, but after work I took it to run some errands and only made it about a mile from my house before I broke it. I bounced the car bombing over a row of speed bumps and in doing so I unloaded the suspension enough to pull the RF axle shaft out of the outboard CV. This renders the car immobile, so I had to walk back home, load the floor jack in my S4, drive back to the CQ, lift it up and put the axle shaft back in the CV, drive it home, ride my bike back to pick up the S4, then finally go run my errands.
I removed the whole RF axle to inspect it, and it was clear there is just not enough plunge in the 930 joints for this setup. I then initiated "Plan B", which was a new (shortened) set CQ axle shafts and joints. Good thing I preemptively drilled and tapped the adapters with the 100 mm pattern the other day and ordered some boots to fit them!
To make the new shafts I cut the stock axles in half, bolt them in the car then run the suspension through it's range to determine length for each. I had to drive back into work to machine them (good thing our shop runs 24/7), then bring them home to weld, assemble, install, and test-drive.
Scrapped 930 shafts:

New shafts cut & machined:

First stage of welding done:

Welded, assembled, installed:

With this setup both front tires can sit at full droop and turn freely without binding and there is no danger of pulling a shaft out of the CV due to the added plunge depth I picked up. That's what I was looking for! It took me until just after 3:00 AM to get this far (two hour break to let the axles cool after welding- you want that process to go nice and slow to reduce internal stress and keep maximum strength).
OK- now we are ready to go to Audi Expo! maybe.
An hour before I planned to leave I did a little test staging of the car with one tire up on a log, and it looked pretty good. Then I backed the car out, articulated it weird while turning out of my driveway, bound up the right front inner joint, and shattered the bearing cage.

Super. Duper. Good thing it has a winch to pull it's self back into the garage.
Cue the mad rush to pull the axle, replace the joint (with my last one) and get it all back in the car. Got that done in about 30 minutes so I guess all this practice is paying off. LOL
OK, now it's ready for real this time. My wife drove the lifted car and I followed in my V8 swapped CQ. Car ran flawlessly on the 1 hour drive and I got some special parking on the lawn with the rally cars.
I'm sure some other folks got better pictures (please post them if you do!) but here are the few I took:



Obligatory Sport Quattro rally car photo:

Right as we got close to home, the car started misfiring and running rough. My wife limped it home and I'll dig into that with VAG-COM later. Now it's time for some sleep after a good long day.
