A lot of your questions I don't have answers to, but I have a few. Keep in mind that I'm no expert, so some people might have different opinions.

If you don't have roller lifters, you'll have to get roller lifters that are designed to work in those older apps. It should say in the descriptions which ones these are.

Order a catalog from Mustangs unlimited, they have a lot of helpful info in them. Also check out some Mustang websites for answers, like corral.net. These are common questions to them.

If you are going with new alum heads, you'll want to buy new roller rockers, too.

The flywheels and harmonic dampeners are generally available in 3 (un)balance weights, 0 oz-in, 28, and 50. Finding a new flywheel won't be hard, but you do need to identify which one you need. The late model HOs use the 50. Most of the 331 and 347 stroker kits use the 28. If your engine is older, then it probably is 28 or 0.

Cooling, you'll probably want over 2200 CFM or so capacity. The more, the merrier. A clean 260 V6 or diesel radiator seems to work, but may be marginal when they get older. A corvette radiator has ins/outs opposite of where you want them. 240 Diesel would be the easiest, but there are aftermarket aluminum rads out there that fit almost perfectly as well.

All the intake manifolds are generally compatible with all the heads, you just want to match RPM ranges with your goals. For 400 hp out of 302 ci NA, you'll probably be looking at higher RPM ranges, like 2500-6500 maybe?

Shouldn't be any hood clearance issues. It sits pretty low in a 240.

Headers: The new FRPP headers seem to have an odd shape that is not that great for Volvo conversions. The ones from BBK or Mac look "normal" and should fit ok. I have Mac. Maybe needs a little dent where it comes close to the steering U joint.

You should still be able to buy the 260 bars from IPD, even though they haven't been listed for a while. Just call them.

Hope this helps,
Greg
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