A FEW SMALL UPDATES.....
Over the last week or so, a few small bits of progress happened.
First, I pulled the truck off the monster-jackstands and rolled it back outside. I will probably re-think the way I had it lifted up and center it properly under the mezzanine next time so I can do proper bump/droop experiments at full suspension travel in all positions.
Here's a 3/4 shot of that quick-and-dirty 44" arch and flare....kind of shows the "beefier" look that the truck has while still trying to keep everything "subtle and stock":
This one is a bit harder to see, but this rear shot shows the fenderlip stickout vs. tire stickout.
The other thing I wanted to tackle was getting the tank design 100% mocked-up based on the 29.75 Gallon design that I'd drawn up with PencilCAD. That meant that I needed to get the 5.5* taper across the bottom of the tank and lower it so that it was 10-1/2" deep on the bumper side and 12" deep on the axle side. This leaves me with about 1/2 of room underneath for a small air gap under the tank and a strong skidplate to protect it....while still staying hidden from view (side view) by the taper of the rear quarterpanels.
I also wanted to add the small "wings" underneath the framerails. This adds a trivial amount of extra fuel capacity (maybe 1 gallon?) but it does give me a nice flat surface to draw up against the underside of the framerails (with a traditional type tank strap setup). I can run the straps all the way around the bottom of the tank, and straight up both sides of the tank and anchor them at the very top of the framerail with some kind of solid welded bracket in 4 or 6 spots....
With the new tank design installed, it passes the "visual test".... as nothing can be seen from the side. No ugly corners poking down to spoil the view!
This was all important to accomplish and get finalized because in the back of my mind I still need to get the exhaust routing figured out... and it needs a "path" to escape out the rear corners of the truck (ideally) since that's the "stock" look for the truck.

This photo shows the aggressive 45-degree tapers that I put on the tank create a small "window of opportunity" where I should be able to sneak the exhaust from the inside of the framerails, back to the outside of the framerails where they ultimately need to go.
.....and to spell it out more clearly, here's a peek-a-boo shot of a piece of 3" diameter exhaust tubing approaching that area to give a sense of the space and scale.
Some of you who are on BookFace already saw this photo... but Cone Engineering delivered the remainder of the 304SS tubing (all 3" diameter) so that I can extend the headers all the way through to the back of the truck.
Now the only thing left is to find a nice source for stainless exhaust hangers that will work well and look as nice as the rest of the system.
Anyone have a link?
-G