OK, so I spent last weekend creating little tabs to capture all the link mounts, coilover mounts, etc. That takes a long time and requires a complete disassembly, welding, grinding, painting, etc. I'm only working with an angle grinder here so it's not like I can just plasma out a new plate.
Also, in general, a 3 link is somewhat challenging to package because of the exhaust, driveshaft, frame, and so on. I can see why a lot of people just get lazy and run radius arms, but then I also don't really see the point of a SAS if you're going to run radius arms. But that's just me.
Got all that done and resumed cutting fenders. I'm fundamentally at a point where a bunch of stuff is starting to hit monuments:
* Tire to firewall
* Tire to inner fender / fuse box / air cleaner / diagnostic port / fuel lines
* Drag link to frame (when turned)
* driveshaft to AT oil pan
With that in mind, I think I'm getting to a point where I need to limit uptravel under flex more than limiting uptravel under dual stuff. This requires outboarding my bump stops as much as possible, so I built little platforms to go over the knuckles. This may sound counterintuitive, but when the shock/coilover is fully compressed, the tire has plenty of room ordinarily, but then when the other side droops out, the whole axle pivots about the bump stop - meaning the tire will keep coming up and into the fender. The front is especially annoying since tires turn, etc.
Making matters more complicated, domestic axles typically use more caster and less kingpin axis inclination, so you just need to keep cycling the suspension and checking stuff out.
Overall, though, the good news is that all the typical problems with a SAS (frame interference, etc) that require massive amounts of lift aren't a problem - I just am dealing with tires that are a teensy bit too big for this platform. I said this with my 80 build, so I'll say it again here - 40s would be way easier to fit. But now both my rigs run the same kind of tire, which is nice.
Here are some pictures
For those wondering, the rear a/c seems like it'll still work. So that's a plus.