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Whatever you do, work fast. Get the engine running ASAP to stop the corrosion. Important, before you start cranking with the starter crack the drain plug. If you've got water there you'll want to change the oil first.

Resistors NEVER fail in a mode that causes full voltage to pass through. If you are getting full voltage through that means all of your glow plugs are dead.

Sounds like your batteries are dead. How did bypassing the glow plug resistor solve your problem? Did you install 24v glow plugs.l?

The performance ratings aren't usually published for air filters, that makes it difficult to compare brands. Napa, Wix, AC Delco, Hastings, etc... all tend to sell decent filters. I am not a fan of Fram, Champ, and K&N from experience. I would be hesitant to install a $2 air filter. Even Fram...

Yes but your 6.2 might experience valve recession from the extra dirt passed by the inexpensive filter. Air filters are not an item to cheap out on. I put a Donaldson PowerCore on mine when I did the turbo conversion. You can see daylight through the filter in the picture of the cheap one.

There is an important ground strap to the block. It's behind the fuel filter housing off the passenger cylinder head. I forgot to reconnect it once. My brake lines were smoking during the glow plug cycle.

A 100 amp alternator will take about 45 minutes to fully charge a dead battery. I would start your diagnostics first by fully charging your batteries, 12.6 volts. Put them in the truck and start it. They should immediately jump to 14+ volts if the alternators are working. If the batteries are...

I guess it's a little more complicated than the gel I use for ultrasonic thickness gauging.

Ultrasound gel is glycerin if I am not mistaken.

It takes a very involved fire to get magnesium going. The vehicle would already be a total loss by the time the magnesium starts burning.

How hard is it to drop the pan on the engine? One could plastigage the bearings. If they're found to be worn, roll in a new set.

Straight 30w diesel oil is rare. 40w was the standard grade. There is a 20w40. It's zinc free for engines with silver faced bearings. Runs fine in a John Deere 4045, though. Maybe it's not so good if you have a flat tappet cam.

If there is no drop there is nothing happening. In that case do be suspect of the pilot side of the circuit, the signal to the starter relay.

What does the battery voltage do when cranking?

If it uses the same principle behind MLS gaskets, Viton rubber on steel shim, they'll do fine. If I knew about them previously I would use them.

Interesting, I saw your picture and assumed it was just new bolts. I've never seen an axle flange gasket. As long as it's metal backed it should be fine.

I do recommend using anaerobic gasket maker on the axle flange. It doesn't seep like silicone does.

The square bodies have a very shallow firewall notch so length is an issue for many swaps. Electric fans can free up space on the front of necessary. The frame rails are also somewhat narrow so look for routing options for the downpipe. I put a center mount turbo 6.5 in my truck. I had to push...

There is no component that is specifically prone to leakage. Renew the old seals and use as few gaskets as possible. I built my engine using only intake manifold gaskets and a water pump gasket. Everything else got anaerobic gasket maker or RTV. Transfer case was done with anaerobic gasket...

Every GM V8 I have opened has had a worn front cam bearing. Definitely a good idea to renew.