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    Whose fault is it? Rear control arms or springs?

    Don't even think of crawling under the car with it sitting on concrete blocks, they can crack and disintegrate to little pieces in an instant. Stick with wood (4x4s) or metal only. (seriously heavy-wall tubing, or short sections of thinner wall tubing (0.25"+) that has the ends capped with...
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    Online Buyers Guide

    These guys don't have any performance parts, but they do have quite a few replacement parts for '64-'09 stangs at decent prices. Even sheet metal for early cars. Car Parts Discount - New Auto Parts No free shipping though.
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    How much sound deadening (dynamat etc) is needed?

    How is the factory deadener attached? Isn't the idea just to add some mass to the sheetmetal to lessen high-frequency vibration (sound)? Wouldn't think it would need to be too high-tech.
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    What should tire pressure be at to prevent flat spots?

    Old bias-ply tires were prone to flat-spotting, not modern radials. (parked for a reasonable period, I'm sure twenty years without moving might do bad things)
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    4.10s in and making noise!

    IMHO absolutely do a check with gear mesh dye, it's the only way you can know where you are with the pinion depth. Even if you were installing brand-new factory gears you would have to do this. And aftermarket gears have far more variance. Some brands of gears are stamped with the pinion...