I think y'all are on the right track, I always recommend a 4BT as the most practical and simplest swap for our trucks. (although I have not done it, only thought about it) However, if you have a COE a 6 cylinder like from the dodge trucks would probably be a better choice for the better power and more room available.
I was considering a COE for my diesel, but I decided I wanted better accessibility for working on things. I may be wrong, but I think a normal truck will be easier to work on, like to adjust the valves.
As for overloading my front axle, it is from a Chevy 3500HD with a v8 diesel, and is rated for plenty more than I will ever have on it. The weight in the front axle in the truck it came from is more than what mine will be. It is also physically larger and stronger looking than the 2 ton axle I took out.
And the noise, I am going to do everything I can possibly do to insulate the cab from sound. I will also have the exhaust come out at the rear wheel on the right side. A good muffler will help too.
