Awesome write-up!
One question - Looking at the stock and BMB knuckles side by side, it looks like the steering arm is a bit shorter on the BMB knuckle. I suspect this is just due to the angle of the photo? Otherwise this seems like it could result in some reduction in steering leverage?
This pricing agrees with my previous total A/C replacement. Add $100-$150 for a vacuum pump and manifold if you don't already have one, then you're at about $700-$750.
Just wait till you try to shop for insurance and they count up claims. Then it doesn't matter how much the claims were for and you're stuck. Insurance is a racket. They're not in it for charity, in fact there's a ton of profit in the minutia.
I used to rely on insurance for towing and windshield replacement until I experienced what happened to rates if I ever used the coverage. Now I pass on the insurance and use AAA and just pay for new glass when needed.
I've learned to only insure and file claims for catastropfic events and...
A used Tupy head in decent condition would likely provide many years of service. I'm sure there have been Tupy heads that have cracked, but I personally haven't heard about one.
ProMaxx is likely your best option for new. Will you be reusing the valves/springs from the cracked head? If...
I recently attempted to install a new blower motor and had a similar issue of it not running. I checked everything including resistor and tested 12V at the connector. Turned out to be the connector on the blower side that didn't want to seat fully. I ended up putting my old blower back in...
I should have added that spacers are mandatory with 12.5 width on stock wheels. Many understandably don't like to run spacers, but if they are of good quality, are properly installed, and maintained, they are a safe alternative to custom wheels.