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I did head studs on mine when the head gasket blew, best thing I ever did. I noticed a difference in pitch when the engine is running and it runs cooler, plus when I get my turbo it will be able to hold the head on the block! As for the bottom girdle, most of the performance shops I work with...
Cool! As for the transfer case the 97 won't work it drops on the left, your case drops on the right. Yes your right I hope you can get the wiring harness that will save a ton of money! As you get more stuff keep us posted with pics!!!! I like to see projects like this!
If you can find an np205 that is a 32 spline input shaft and a round bolt pattern than it will bolt right up, the np208 or np241 will also bolt right up, the np241 is a little bit beefer than the np208.
http://www.advanceadapters.com/products/50-0410--gm-4l80e-to-gm-np205-trransfer-caseadapter-kit-replacing-th350-or-sm465/ that is the adapter for the np205 to 4l80e
WOW! nice find! As for the linkage and shift indicator, the stock one on your cucv will work. If you want it to read overdrive than 3,2,1 LMC sells the overdrive indicator for about 20 bucks, will fit in your stock shift indicator location and is the origanol look as well! Is the transfer...
If it where me I would just rebuild the 6.2, if you are dead set on the 4l80e than try and find a really cheap donor truck for the harness and trans. Dropping the 6.5 and 4l80e is not a bad idea either, you will have the 6.2 out for the rebuild so just dropping the 6.5 in would be much faster...
if he gets the whole donor truck with the trans and motor, than all that is needed is the wiring harness and computer from the donor truck to control transmission.
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