Not sure your going to be able to get the c4 knuckles to work for all wheel drive. And I def would not cut the backside open on the closed ones for strength issues. The c4 and c5/6 knuckles run completely different hub packs. I haven't put the c4 spindle and the s-10/blazer hub packs near each other, but that may be a possibility if you can check the bolt pattern and other clearances. Or you may just look at the s-10/blazer front spindles for the 4x4's. I believe they were the same spindle assembly for the syclone, typhoons and bravada awd vehicles.
I have not looked into the sts front diff yet, but there use to be a couple options out there, one was taking the 4x4 s-10 front axle diff setup and you have to swap out a couple parts to make it awd(there is tech over on syty.net on that). I was originally looking at a ford front axle so to have more gear options. And if you haven't found out yet, the gears are diffrent for the front diff typically. Some of the srt8 jeep cherokees are awd, so that may also open up some possibilities.
The hardest part is trying to not have a lot of specially built parts and to build it strong.
Not sure what trans you were looking to use, but auto is typically the easiest way to go without having to have custom machined adapters. Pretty much awd vehicles are auto that you are going to be sourcing parts from. The Audi, Subaru and others that have manual option have a far forward mounting engine with a crazy looking trans axle design that would kill the weight balance in most projects like this. Their front axle comes out of the front of the trans about 6-12" or so behind the motor, think about where your front axle is and how far forward the motor would sit. Chevy had the option on the silverado truck and trailblazer ss more recently for awd along with the cadillac ext truck. They hung a awd viscous coupler transfer case off the back of the trans. It's in the same area as the 4x4 transfer case but instead of being gear mesh driven, it is chain and fluid.
Not sure if any of this helps, but it some of the stuff I have found a while back when I was researching, lol .
Robert
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