I've been away for a while, and just took a closer look at the inputs you made to the suspension calculator in post #757.
In "Unsprung weights", you put 220 lb front, 230 lb rear. The calculator doesn't make this clear, but those inputs are supposed to be "unsprung weight per side in front" and "unsprung weight per side in rear". It looks like you put in total unsprung front and rear weights, so for example, the calculator is assuming your unsprung weight per front corner is 220 lb, not 110 lb like you mentioned your text description.
This is verified in the results. Look at the "Sprung weights" in the upper left corner of the results, and compare them to the total corner weights you entered. Basically, the calculator says you have a total of 900 lb of unsprung weight. Not even heavy-ass chrome wheels from the 1990's would make the unsprung weight THAT bad, ha!
Thanks for the clarification. I replugged everything in and updated the ride freq to 1.8/2.0 hz. It looks like 300/350 spring rates would work well.
The Mustang struts have been kicking my ass in the CAD model. They hit the control arm/ball joint unless I make tubular arms with a jog. Once that's solved, they hit the tie rod at full lock.
Moving the strut centerline further back on the knuckle now messes up the brake mounting bracket, so that's annoying.
I pulled the trigger on a pair of Gen6 ZL1 front struts. They look shorter than the Mustang struts, but the Rock Auto measurements have already lead me astray on the Mustang lengths.
I bought Chinese OE replacements off Ebay for $260 shipped for the pair. Mostly because it'll be easy to ship them back if they don't fit.
I'm also annoyed that I've already cut up one of the Ford OEM struts to mock up the coilover sleeves. It feels less bad to cut up cheap Chinese struts, at least.
If they ohm out the same as OEM (1.2ohm), It's worth a shot.
There are plenty of mostly-positive reviews for knockoff replacement Mag shocks out there. Mostly for GM SUVs, but hopefully these are decent.
BWI (Beijing West Industries) is the owner of the Magneride IP and manufacturing, so it's entirely possible these were made on 4th shift and left out the back door lol.
They're supposed to show up Wednesday, so I'll get them measured, scanned, and into CAD.
