Here are the new links laid out. One at the shortest it can go and one at the longest. I ended up somewhere in the middle.
This is my first time messing with the front end to this extent by myself. So lets just say I learned a lot. I started with leaving my lower control arms the way they were and then setting the upper link to a length that looked about right. Then checked the caster using my phone (shown below). Then I adjusted the upper control arm length until I had about 6 degrees caster. (you can barely see it in the picture, but I attached a screw to the lower nut on the inner C to extend the line out so I could see it). See ... 5.96 degrees.
Once I knew the link lengths were going to give me the right caster, I took a look at the bump stop alignment at full bump.
The above picture was after one large adjustment, I forgot to take a picture before. But as you can see, it is still off. I then shortened the control arms another half inch.
That's more like it. I still don't like the fact that the pucks are angled back, but there isn't much I can do about that unless I want to cut the brackets off and move them, and I don't. I removed the links 4 different times trying to get the alignment right. It was good to have them out though. The lower links needed some work. The flex joints were loose and needed greased. So I took the time to clean, adjust and lube them. Also inspected the bushings at the axle end of the lowers, they looked good.
Then it was time to hack off the top of the passenger side axle mount. The directions say to cut 2.5" up from the axle tube. I did that, then I had to bend the remaining bracket back into shape and insert the provided bracket. Shown here.
And some more pics of the links before welding up the bracket. This is where I leave it tonight.
