I hadn't considered the axle itself being heavier. In regards to the cost, a quick online search found a new 9K axle at $1,100. to go tandem I'd likely need to buy two new axles so that the suspension is tied together instead of two independent axles under the same chipper.
I'm not sure I follow this comment, from the sounds of it we're both already pulling a single axle chipper with no issues. What's dangerous about a single axle? As for tongue weight I think there's no doubt that there will be extra weight. Its already tongue heavy by design and were talking about extending the frame and chip chute, and adding a platform to the front. When loaded it will be 1,000s of pounds heavier on the tongue than stock.
Just kicking around ideas in case I do go this route, I'd much rather not have to do it all again once completed because I over looked something.