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When you get your dash pad, put it in direct sunlight for a few days. If it's anything like the last couple I received from Year One, it'll start to de-laminate in short order. Your better off finding out now than after you install it.
Ricks kit combines both oversized pins for the lower hinge and bushing for the upper. It's worked well for me in the past and he gives you the option to purchase the reamer as well.
http://www.restorick.com/proddetail.asp?prod=DrHingeRebuildKit
If the piece is supposed to be perfectly flat, I'd wait until the little women is out for the day and chuck it in the oven. Bring the temp up slowly and keep an eye on it. Once relaxed, bring the temp back down and it should stay flat. This will help keep the heat evenly distributed.
Here are a few sources for connectors. Not necessarily stock, but will work.
http://www.electerm.com/weatherpackterminals
http://www.mouser.com/Connectors/Automotive-Connectors/_/N-1ehb5/
....and if you decide to get it blasted first, make sure you use someone who knows how to blast automotive sheet metal. More cars have been ruined by guys that are accustomed to blasting bulldozers.
I've found the AMD floors fit pretty well, so you should be okay. Like Fly said, remove the old floor just shy of the pinch weld and work the remainder off one spot weld at a time.
It's probably too late for this suggestion but you can always leave the flange and cut the floor back two or three inches and just butt weld it (assuming the original flange is in good shape). This will save you the hassle of dealing with the spot welds and also make up for any variation in...
Pictures. Take many, many pictures. Many more than you think you'll ever need during the entire process.
You'll be amazed how a year from now you'll need to reference the most mundane item.
Also, if you're going to pull the axles completely out, wrap a cardboard tube around the axle ( when it's partially out) and slide it halfway into the outer seal. Then pull the axle fully out while holding the cardboard in place. This will protect the seal form the splines of the axle as they...