Ive found the best way to cut the line is with a ratcheting pvc pipe cutter from lowes or home depot.
Dont have to deal with all of the dust from an angle grinder. Also safer. Best way.
The pulley most likely fine, you can replace the bearing if you want. Or you can just buy a new one so you have a fresh spring.
Metco also makes a brace to support the stock style tensioner
Absolutely get the full billet idler set. Metco is the best in the business. I prefer to support them, but there are cheaper options. You can also wait until you see some used pop up, the bearings aren't super expensive. 6203-2rs
Get you a new intake gasket if you haven't put together yet.
https://www.lethalperformance.com/ford-oem-2003-2004-cobra-manifold-to-head-gaskets-pair.html
Pretty cheap at lethal, vmp charges like $200 for the pair. Id also replace the fuel filler neck grommet when you drop your tank for the...
I can't say enough about how great Fore systems are. Clean, easy install. Buy once cry once. Fast shipping. Best of the best in the business. Worth the money in my opinion.
Looks awesome. Did you paint the intake and covers or were they powder coated? Where did you find a good match for the oem finish? I want to redo my 03's eventually.
I think the best course of action is to befriend people with said cars you enjoy. That way you don't have to buy them. I'm keeping the 03 for as long as I can. I've got a close friend with a twin turbo Boss if I ever feel the desire for the s197 experience.