...So I'm looking at other options, one of which is figuring out how to use a 2nd gen hub. From what I can tell, the only difference between the 1st and 2nd gen hubs is the spline count. The bearing is the same for both gens and so has the same ID and OD so that means the hub has the same OD.
One bright idea is building a custom axle with 23 splines for the transmission output and 26 splines for the hub.
Does anyone here know 2nd gen and later parts enough to know if this would work?
I wouldn't use 2nd gen hubs if I were you. Biggest reason (IMO) is because those hubs are actually weaker than the 1st gen hubs are. Another is because I've been seeing posts from folks that are currently racing them mentioning that those hubs are no longer available from Honda either.
As you have discovered, they use the same bearing so the outer diameters are the same, but the diameter of the splines on the CV outer end are a slightly larger diameter than the ones on the EW axles. That makes the wall thickness of the hub thinner. I seriously doubt Honda made them out of a stronger material than the earlier versions when they designed the 88 and later cars.
This would explain the rash of broken hubs from those models when they were raced back then. Also why the OPM guys at the time went to the trouble of selling hardened ones, which did extend the life of them in race situations. I remember a friend of mine had, I believe, three hubs break on his 88 Si when he was racing it. Once when I was at the wheel during an enduro at Road Atlanta, luckily I was going in a straight line at the time so I just coasted to a stop. The worst was when he ended up on his roof in turn 7, again at Road Atlanta, except this time it happened during his SSB Runoffs race.
Not trying to discourage you from trying other options. Just sharing some of my experience.
Jay