So we had a few problems with the drivetrain at NCCAR, which were fixed over the week. The combination of the relatively large half-shaft angle, improperly sized half-shafts (too short), and tripod housing that were not deep enough caused the drivetrain to fail.
The new tripod housings have a lip built in for the boot.
In addition, we had a lot of trouble aligning the drivetrain. There was a lot of movement of the bearing carriers due to the misalignment, so we had to unpress things, make spacers, mill down a diff cap, and eventually everything aligned well enough.
After driving yesterday, the drivetrain seems fine. Nothing broke, so I think we're good to go.