Sounds good, but what about the bowden (hood latch) cable? Does that come out of the cab, or do you disconnect it from the latch and snake it out of the clip?
Good question to bring up I neglected that one small Item, thank you.
Actually there is a small clip that holds the cable to the latch, I just slip off the clip, then fish the cable out.
The bottom line is that it is really very simple to remove the entire front body work.
Ya sure those core support bolts might break, and they likely will...So what? What happened last time you broke a bolt? Did you fix it? If they break they are weak and need to be replaced. I'm soaking a pair right now as a matter of fact.
I found no need to lift cab when I remove the front clip, however I suppose it could be good. That just means more work, brake MC Steering and such.
The wire harness that loops around the inside of the fenders stays there when you remove the clip. You just undo the connectors on the drivers side by fire wall. Disconnect the engine harness from the main harness and that is it.
I don't even pull the rad out I leave it, I do however remove the shroud from the rad just unbolt, let sit on fan...
Simple, done this many times on these trucks and wouldn't do it any other way!
On my Bronco I can have the clip off in about an hour or less. All bolts well lubed and it's been on n off a couple times.
On a truck that's rusty, or not as prepped, it takes a bit more time say, 2 hours tops, now these times are with AIR and electric impact tools not just ratchet n wrenches.
Any way you choose, you live with consequences, such as body line alignment and various other things, removing rad support is less so as it's just one small part of puzzle. Just bag the different alignment shims and mark the LH or RH on the bag keeps it all easy!
Seeing as you likely are going clip off you'll find that it allows you TONS of room to clean the frame and parts and your D60 swap will be simpler as well. I'd strongly suggest that as you mentioned, it's likely going to snowball, and that this is best time for frame paint etc.
JM2CW
Al