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Do I have to replace the gaskets for the timing cover, front main seal, water pump, intake manifold and valve covers? I note that some of these are rubber so they may still be fine to re-use? I see kits with all of these but not sure if I need them all until it gets opened up.
I would do the front seal, timing cover, and water pump as they're 15 years old and it is pain to do it again. Water Pump you could likely reuse but again they're 15 years old and I don't enjoy draining the coolant.
Intake, I'd likely take a look when they come off and decide. Valve covers, I would not if they are not leaking. Also while you're in there take a look at the little gaskets around the bolts which attach the valve covers to the head.
I have been looking at some new rocker arms with BTR trunions already installed. Are the bushing by Smith Brothers better than the roller bearings used by BTR? I suppose that may be somewhat subjective but it does look like the bushing type is more expensive.