Very nice Danheit, My body mount brackets are 3.5" off the frame on the rears and 3.25" off the frame in the front. Total height for the brackets is around 7" rear and 6.5" front. With the S10 body mounts, it sits the cab about 4" off the frame, nice and level. I used a 3" air cutoff for all my cutting. Took FOREVER. I made poster board templates for all the pieces, so they were the same left to right.
Good thinking on the ducting from the Tahoe. I will definately take a look at it and pull it if it'll work. I think his whole reason for the bench seat is so the future girlfriend will be able to ride center...
He doesn't want a console at all...
On defrost, I think I can make a small plenum under the dash, re-using the stock temp control knob and cable to move a door and allow the heat to be used as defrost as well. Plenums are not that difficult to design or build.