Thanks for coming out Josh and James, it was nice to have company. It gets discouraging wrenching on this every night with seemingly no progress. It was good to talk to people who have been there. You guys rock, feel free to stop by anytime.
I finally got the six shooters adjusted with the right preload. My lower trunion bearing was a lot tighter on the lower cap than on my original knuckles, which is weird since it's the same cap. Regardless, it went on with some "persuasion", and the knuckles are all shimmed up perfect to 13-14 lbs. Working on the knuckles isn't hard, but it is time-consuming. I must have pulled that steering arm 6 times per side till I got it just right. Note to those installing 6-shooters: only install 4 of the 6 nuts/cone washers when checking preload, it saves a LOT of time when you have to pull it off again. I'm glad I now understand the mystery of Toyota knuckles. I was always unsure of what they were, how they worked, and what they did. Now I know.
***side note for those who are curious: i put one thick shim on the bottom trunion cap, then it took a medium and a thin shim on the top one. I'll post up if this setup gives me any problems. My stock knuckle had a thick and one thin on the bottom cap. I'm hoping this is somewhat close to centered on the axle. The last thing I want is a front seal leak after all this. I'm sure if I'm off even by a little, the Marlin Ecoseal will help things stay where they're supposed to.
Now I have to grind out the inside of my ball ends to clearance my dirty 30's (I assume, haven't put them in yet), then the front axle will finally go all together. I've never done this before. It can't be much harder than anything else I've done so far. I sure hope my housing isn't bent and that my knuckles are somewhat close to centered.