While preparing to straighten my factory 1969 B body D60 housing, I noticed that the passenger side axle bearing bore diameter is 2.875", while the driver's side measures 2.940".

The outside diameter of the wheel bearing race is roughly 2.875" which means there is around .065" clearance on the driver's side.

I see no indications of damage or modifications, but .065" slop seems excessive. Are my suspicions correct or did mopar design one end to have a bunch of slop to accommodate manufacturing tolerances? Does anyone have a bare D60 or 8 3/4 housing that they could measure?

I've resigned myself to most likely having to buy and install a set of Moser axle housing ends, but thought I'd verify with the mopar brain trust before lopping off the ends of my factory housing.

Thanks!

I would do .030 shim stock the width of bearing before I’d cut those ends off.

That is a first I heard of that, not good
I would look closely at the driver side end for evidence of the outer bearing race spinning in the housing tearing it up

Just have a machine shop make a press-in sleeve to reduce the diameter of the oversized end. Easier and cheaper than replacing the ends.

that was going to be my suggestion as well.
when the sleeve is pressed in, watch how the axle goes in. if a bit of jiggering around is necessary, it might be a good idea to check that tube to see if it's bent.
also, it's common for a pressed in sleeve to "shrink" a couple thousands of an inch on it's inside diameter when installed [depending upon the amount of "press" fit] thus, requiring a slight hone to the desired fit clearance.
a way easier [and cheaper] fix than installing a new bearing end.

That's going to be a pretty thin sleeve to press in. Might consider freezing it and dropping it in. A little red loctite would't hurt.

Like I said .030 shim 3/4” wide, 360 degrees, epoxy it in with an old cone, it’s tight.