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Pete,
Empi in fact makes two different styles of drive flanges. The ones with the "HD" bolts (3/8) and ones with stock (M8) I went through this myself. I eventually got a pair with the M8 thread. I think Greg got mine through Rancho. I know Cip1 only lists the 3/8.
You should be able to drill out the CVs if that's the route you go. In a drill press, use a slow rpm (200 or slower) and a fast feed on the handle. To my recollection CVs are case hardened on the wear surfaces for about 1/32 or so. So you shouldn't have to worry about contacting that. If in fact there are a few hard spots, you may need to sharpen the drill a few times. Just sucks that you'll have to clean and repack each one to ensure no chips get lodged in there! Best of luck!
Alex
PS I have stock axles/cvs and flanges you can borrow for the trip if that helps.
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1970 Bug
2110cc. ???Whp, ???Ft/Lbs
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