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240s have this thing with the sides of the trunk areas, there always seems to be some toys/change/goop (I use the term loosely). One of the first things i do is empty the trunk completely, both sides, and wash it with degreaser (there are plugs to run water out on both sides and in the middle of the trunk area, take them all out and be liberal with water) and inspect the seam glues, then paint inside the seam glues (pics in my thread, again) to prevent future rust.
You seem commited, best of luck, I enjoy seeing your pictures and if you keep posting I will add whatever I can along the way.
As to your pictures above about the headlight, the "chrome falling apart" is a common feature on all 240s (it isn't just yours) however the way it is strapped up, and the cheap HID component are an eye sore. I would go back to halogens, or use some REAL HID retrofit lamps (Like lexus RX300 with philips bulbs, w/ modified plates). I actually have a set but the cost is preventive (est. $800 to retrofit with real ballasts and modifications).
You can save some money by sourcing an OEM exhaust system. The factory exhaust will support 300rwhp and is perfect for a stock sr20det. Its exactly the same thing on our cars that comes on JDM silvia with sr20det anyways.
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