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First of all, I gotta say congrads on this build!
Wish I could see it in person for myself...
Gotta love the link to the dumb club...
(Bent axle shaft? Are you for real?)
Only really useful info was the sheer pin reply.
Gotta narrow down the problem to either a resonance problem (which is sounds like) or a out-of-spec part (which would usually mean +speed = +noise, which doesn't sound like the case).
Let's concentrate on this as a resonance problem...
Do you know what your caster spec is?
Too little caster can cause your headaches.
Another more than 5-degrees should be okay - I would worry of caster is less than 5-degrees.
Since you basically did a front steering / suspension retrofit and others have complained about the same problem, I would tend to blame the retrofit itself as the problem...
-Ted
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