We want something dependable that could be driven at 60mph or so for 100 mile trip.
Hey Mike. Is that all the customer is going to do with it? If so, why the need for more than double the original power in the Bronco? Yes, it can be fun, but who's going to be driving it, and do they want to end up on one of those YouTube compilations of epic fails when too much power gets in the wrong hands?
Is this person familiar with the handling characteristics of a 50 year old utility truck? Just checking, in case this is a new-to-you customer.
I was originally going to say an EFI 351 or stroker too, but for cruising and having fun a stock (literally stock) Explorer 5.0 with the aforementioned 4R70W automatic overdrive and the correct differential gears for the tire size, and you've got a sweet combination. Easy to fit, easy on the pocket book, easy on the equipment, and just a really nice combo.
It's what I've got in the '68 and I'm going to change the gear ratios to get more speed, hopefully more mpg than I already get (which is pretty darn good for a Bronco), and LESS power. Yep, you read that right. Less power to the ground.
Right now I can hardly keep the tires from smoking, with 4.56 gears and 31" tires and the power of the 5.0, accelerating quickly is a challenge. And I can still get 20mpg on the highway.
Granted, for me a set of larger tires with all-terrain tread would be a good alternate solution. But I already have the gear setups so it's just a matter of labor on my part.
The stock Explorer is admittedly a little anemic
by today's standards at only 240hp or so, but that's still roughly 100 more horsepower than a stock '72-'77 Bronco 302 had. Just think how much fun that 100 extra horses is, without the need for another 100 on top of that.
But you have to figure out exactly what the customer wants, needs and can use and that will help determine the outcome.
A 351W with EFI and some programming can lay down 300 to 350 reliable horsepower very easily. But remember what else might break downstream from that power and torque too, given the right (wrong?) right foot applications.
Are you gong to be updating the differentials, axles, and other stuff while you're adding power? Might be worth checking into how the customer intends to drive it.
And remember, with decent power and the wrong gearing, everything between the engine and the tires takes a huge beating. Hence my constant blathering about correct gear ratios and their importance in the happy-camping aspects.
Anyway, that's all just my old man nanny side talking. If the customer knows what they're doing, what they're getting into, and how to make it all work and have fun (and keep the family safe) then a Blueprint crate motor in the 350hp range would be a slick and racy setup. Check out their prices, or check out Summit crate motor pricing in any size Windsor family engine that gets you there.
Good luck!
Paul