The axle has been reinstalled, with air tight cv boots this time ! So far so good..... I even drove it to work tonight ! woohoo
I was talking to a mechanic friend of mine and he mentioned that if the cv boots were to get air in them that it could help pop the cv out... So, I made damn sure both ends had air tight cv boots.
The more I think of the differences between each axle, that was it, loose fitting end stops... I did replace both passenger side Q45 housings with ones that fit the end stops GOOD and TIGHT, like my driver's side is atm. When I used my first pair of Q45 housings, the passenger side end stops were allowing air to get inside the cv boots, creating pressure and helping push the cv guts out. However, I also needed to add that extra end stop material regardless of that theory...
If the axle holds up tomorrow morning coming home from work, it's off to the dragstrip to test out my new VLSD