She's back on the road! After a long winter of fighting rusty bolts, I finally got her back together yesterday. I carefully drove her around the block once, and she seemed to drive and shift fine. I haven't noticed any leaks from the transmission or the brake lines. I'll try a longer drive tonight after work and see how it goes.
Parts replaced:
Passenger side only: Axle.
Both sides: Control arms, tie rods (inner and outer), ball joints, flex brake lines.
Parts saved: Fender (I straightened the bent lip). Wheel well trim and lower cladding were slightly damaged but I reinstalled them.
TBD: Passenger front tire and hub. The tire held air all winter, but I need to drive at higher speeds and go around corners to evaluate the hub and tire.
Total cost: About $400 including tools.
Time spent: I don't want to think about it, probably 50+ hours if you count watching videos and buying tools.
It doesn't sound like much, but I found ways to make the project take forever. It was my first time doing any of these jobs on any car, so it was a slow learning curve to figure out what technique to use. I often would only have two or three hours a week to work on it, so it dragged on and on. I tried to save money by using the wrong tool for the job a few times, which just ended up with wasted time and frustration until I would give up and drive to the store and buy the right tool. Once I had the right tool and the right technique, each job wasn't bad. Moral of the story: Buy the right tool!