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I built a custom 2.5" exhaust from header back and used a borla pro XS. Nice deep tone until 3000 rpms where it opens up and gets loud and slightly raspy
I have a buddy that ran the e350 master in his zj with a stock dana 30 and a 8.25. I run the 98 durango master and xj double diaphram booster on my dana 34 with 78 bronco calipers and a ford 8.8. Needed the slightly larger bore to move enough fluid for the front calipers.
Not sure how you feel about Rustys but he has a replacement with bushings for 70 bucks.
http://www.rustysoffroad.com/builder-parts/brackets-mounts/builder-control-arm-mounts/rustys-control-arms-front-upper-mount-kit.html
Rufff stuff specialties sells an offset tie rod end. GM 1 ton taper and I believe it's 7/8--18 thread.
http://www.ruffstuffspecialties.com/catalog/merchant.mvc?Screen=PROD&Product_Code=TREOFF&Store_Code=ruffstuff
6 planetary can be found in a 241 from full size Chevy. Of course you'll have to change the input shaft to your jeep input. The 1 1/4 chain and gears, including front output shaft, can be pulled from a 231c out of an S10. Some S10s have a 231hd which have all those parts and are much harder to...
I've run Chevy wheels on jeep before. 5 on 4.75 bolt pattern. I redrilled the bolt pattern on the axle shafts and discs in the rear and the unit bearings and rotors in front. Not sure if there is enough meat to go to a 5 on 5 pattern for the jk wheels. I'd have to compare the flange diameter and...
I bought the Clayton swaybar brackets then found out with the 1 ton OTK setup they were too low. Your design looks like what I had to do to get over the draglink. Raised mine 2.5". Wish you would have had all this when I did my WJ and 1 ton steering 2 years ago. Prototypes look good.
If your determined to run 5 on 5.5 there's always the Dana 34 option. That's the route I went with WJ knuckles, dana 44 spindles, hubs, brakes and lockouts. There's machine work involved but not a lot. Here's the link to what I used to start my conversion...
Had a buddy that just bought a set of rock rings from TMI. Standard is 3/16 but you can get 1/4 from them. 100 bucks a set. Here's the link.https://totalmetalinnovations.com/index.php?main_page=index&cPath=4