2013.08.08 - UPDATE! - I AM AN IDIOT...... 
Some garage days are just the worst.
Last night I hadn't been in the shop for more than 3 minutes, breaking loose the very first bolt of the evening and the wrench slips and smashes my finger.
I said bad words.
Moving on from that it seemed like a good time to just put the old wheels and tires on the axle and start looking at clearances around the various parts just to confirm that nothing had gone horribly wrong. It didn't take long to see that a few "tweaks" were going to be necessary if I wanted to tighten the wheels all the way down to the hubs.... this happened about 1/2" before the wheels were seated properly:
Oooops....
Not a real big issue. I'd built those steering arm plates a little long on purpose just to be safe, so I nipped the offending corners off on each side and the tires bolted up fine (good enough for now anyway). Right about this time is when my frustration really started to surface....
For many days and weeks now, I've been telling all of you about my 23" lower link bolt measurement being my "reference" for ride height. Well, for some reason when I went to mount the wheels the wheel studs seemed awfully high compared to the wheel I was trying to mount.
Um, yeah..... so it turns out that the true ride height value for that lower link bolt isn't 23".....it's 21.5".
Yep, I'm an idiot.
Thinking back, I have no idea how the value got so messed up. I remember checking and double-checking everything and even compensating for the slope in the floor when I first leveled the frame and front axle. It's still a mystery how it became so far off, but the discrepancy is not trivial. I pulled some new measurements off the axle to plug into the 3-Link Calculator to find out just how much damage had been done with my bad values. The anti-squat (Anti-Dive actually since it's the front axle) was over 100% instead of 70% where I'd planned for it to be, but miraculously the roll understeer was still intact and most other attributes were pretty decent. It looks like I can raise the frame-side upper link mount by about 1.5" and the AS% will drop right back down to where it was before this whole mess was discovered..... maybe that's a bit of "good karma" coming back my way?
EDIT: My current hypothesis about the bad lower link value is that the measurement was taken when the front axle had zero caster (another accidental oversight) As the axle was rotated backward to achieve 8* of postive caster, it is plausible that the lower link bracket could move downward by 1.5" and throw off my numbers...
In any case, I pressed forward. Turns out pblaze725 called it correctly about the PHB mount creating an interference point with the inside tire sidewall. The forward-most heim bracket was modified to give it more clearance on the radius as a starting point, but that wasn't enough to get me to the steering stops. Ultimately, the PHB had to be shortened by 1" (from 41" to 40") and both heim brackets were shortened as well to shift them away from the tire.
You can see the asymetry in the link brackets pretty well in this photo.
From the top view (see photo below) you can see that the large triangular mounting plate is still at full length (1" too long under the heim area) but it will be trimmed back later and doesn't hit anything at this point.
One very cool (and completely accidental) effect is the way the steering knuckle heim and brackets pass perfectly underneath the large triangluar PHB plate. At first when you see the setup it looks like everything is on the same plane, but as the tire starts to turn left, the SAI of the kingpins cause the steering heim (and draglink heim) to start angling downward as they travel across that area....by the time you'd expect them to collide, the heims just slide right down underneath with maybe 1/4" clearance to spare. It's VERY cool...
(at least I think so)
Final shot of the evening. Full steering lock with no interferences.... Ackerman steering effect is quite easy to see in this image. Inside tire is cranking super-tight compared to the outside tire.
Next steps will probably be pulling the tires/wheels back off and cycling the suspension again just to see if I can get full suspension travel this time around.
Interestingly...... since I had been assuming that my ride height was at 23" (lower link mount) and had been fighting for clearance all the way up to 29" (6" of bump) it will hopefully be easier to get everything to clear now.... my new maximum bump travel value
should only be 27.5" now. Last time around I had a pretty easy time getting to that value and all of the struggling was in the 28" - 29" range where this axle should never be anyway. We'll see....
-G
Tired of your awesome brackets, while mine look quite, well, not so/as awesome. 
