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#1 How much can I notch the frame & still be strong enough to haul something around 3-4 thousand pounds ??? (I plan to plate the top / sides & box the inside, & use a piece of 4" 1/4" wall pipe) I just need to know how deep I can make it & still be safe
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I wouldn't go more than 2/3 of the height of the frame (3" max).
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#2 At what point is it advantageous to flip over the trailing arm mounts ??? (I have a one piece drive shaft, so I don't have a carrier bearing to flip)
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Necessary or advantageous? My 68 was dropped enough that the rear axle tube was inside the c-notch @ ride height. I never experienced drivetrain vibration or had u-joint related failure.
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#3 What is the optimum angle for my shocks to run at (I am building new shock mounts)
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I fabricated new upper shock mounts @ just duplicated what the factory engineered as far as shock angles. I figure it worked for this long, it must be real close to optimum.
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#4 Last but not least, if you were building a long panhard bar to run from the frame to the passenger side trailing arm would you use rubber bushing syle ends or heim joints ???
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Option 'C' . . ...... Urethane. The benefit of heims w/o the noise.