1. You said rust in only one place and you've "been all over the car" ....you must be blind.
2. No, 3 out of 11 clips holding the heater box together is not adequate.
3. So, you did a FULL rebuild of the front suspension using dryrotted bushings?
4. The shifter arm shouldn't be the only thing holding the console in place.
5. When you replace the engine with one from a later era, you're not supposed to reuse the original timing cover/pointer on the newer balancer even though it will bolt on. Yes 5 degrees is a lot to miss TDC by.
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