Awesome thread! I'm late to the party. I think the Dana 20 and possibly the rear axle will be the weak links unless they are upgraded--depending on how you drive it. Stock stuff can last and built stuff can break depending on how it's driven.
Two things I wish I would have done differently.
1.) I wish I would have gone with an aftermarket block. Not so much for the extra cubes but you start with good (thick) cylinders that don't need to be bored so much. I feel this would help in cooling the beast. And the extra cubes would be awesome!
2.) I wish I would have gone with a roller cam bock. The same engine in a roller as mine has an additional 100 HP at redline (which I believe people that build these take them to). At the time I didn't think I was going to "need" more than 415 hp/450 tq. Then I built from the engine back and would welcome more HP. I don't really worry about breaking anything but I don't do full power 6K shifts like nvrstuk LOL. I do always have a new complete rear driveshaft close, though.
Also, I went 9.64:1 CR and I would probably go higher if I had it to do again. Not sure what I could get away with but maybe at least 10.0:1 or 10.5:1 without too aggressive timing. When I had this engine built I wasn't looking for anything crazy but that has a way of changing. It's easier to limit HP with your right foot than add it after the fact. That is if your right foot is connected to your brain. Or with a rev-limiter. My experience is that I would build more than I want up-front as it's cheaper then modify whatever breaks after the fact.
I'm running a carb right now but want to go EFI. Nothing really makes me buy it, though. Interesting reading the OP's research.
There's some questions I had in my build thread that you have. Keep us posted on how you fuel that beast.
