Thank you guys for the support! And suggestions!
mcrews, I read your thread last year, but wow, I should have read it again! I love the idea of using those lumber brackets! We have lots of those at the house we're trying to sell. Also I really like the idea of using U brackets to attach the lumber brackets as I'd rather not screw into the frame if I don't have to.
No tape for me. I've been totally burn out on that.
I will see about encompassing the lower suspension bar.
Sven7, What would you suggest putting between any metal and aluminum in contact with each other? I'm thinking there isn't going to be any place that the two metals are actually touching, because the previous owners had a thick protective undercoating added. I don't like thinking of how much extra weight we're carrying around because of it, but at least future rust will be prevented or at least slowed.
I'm unsure as to what primer you may be referring to. I've heard it mentioned in a couple other places, but honestly, the only primer I know of is paint primer. And that doesn't make sense to me.
And lastly,
I honestly can't interpret your diagram... I wish I could!!
So basically, the end of the belly pan is best when it's level with the ground? That would be easier then trying to figure out this 10 degree angle thing.
Probably the further out the back, the better?