Have just come off a long conversation with Barry W, the long and the short of it (excuse the pun) is that the HTE-859 is the replacement flange for Defender etc with 25mm spline inside the flange, the HTE-859X has 35mm spline to be used with the Maxidrive/Hi-Tough X axles.
The original 110/County and my Drum braked Defender FRC5806 flanges had 30mm spline but were much taller.
The solution we have come up with is to get the HTE-859X drive flanges, machine out 5mm of spline from the end leaving sufficient clearance for the circlip.  Then machine an additional 5mm of thread on the outside so the cap takes up the lost space at the end of the axle.
Sounds simple doesn't it! 
 
The HTE-859X flanges will be on the way this week. 
 
Thanks everyone. 

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