A forged crank is not needed for 500 rwhp. ARP main bolts, rod bolts, or head bolts are not needed for 500 rwhp. Aftermarket valve springs are not needed for 500 rwhp (depending on what cam you run).
The cheapest way to do it from your setup right now:
-Stock crank and block
-2012 Boss 302 rods (or 03/04 Cobra rods if you can find them cheap)
-03/04 Cobra pistons, or a cheap aftermarket set
-King OE replacement rod and main bearings
-Total Seal rings
-OEM main and head bolts (side bolts are reusable, and rod bolts are included with Boss 302 rods)
-PI heads
-MHS Stage 1 PI blower cams
-Nice blower of your choice (2.3 TVS, 2.6 Kenne Bell, D1SC, T-trim, etc.), intercooled of course
That should put you pretty close. You might could get away with stock cams depending on how much boost you're willing to push. But as the boost goes up, so too does the load on the valve springs, head gaskets, head bolts, and intake manifold. So you've just got to be more careful there if you're going big boost (15+ pounds). There’s other ways of doing it (higher RPM stroker with nitrous, or a turbo setup, etc.), but none of them as cheap as above. Of course, there’s a few other things involved as well.
Machine work. Hone and clean at a minimum. Only bore if it’s required. Probably resurface the heads while you’re at it. Contrary to what a lot of people will tell you, balancing the rotating assembly is not required so long as you are using a matching set of pistons and a matching set of rods. I know of a lot of very fast cars around my area running just fine with an “unbalanced†rotating assembly. But if it makes you feel all warm and fuzzy inside, go for it.
Drivetrain. If it’s an auto car, you’ll need a converter, trans cooler, and J-mod at a minimum. A mild build is best. With a manual car, a clutch will be required if you’re going to be driving it hard at all. And depending on how hard you drive it, a set of 31 spline axles will probably be needed as well.
Fuel system. You’ll need injectors. 39 pounders will be fairly close to maxed out at 500 rwhp. 60 pounders would be better. At least a 90 mm Lightning MAF will be needed. And of course the fuel pump. Having a 98 myself, here’s the way I’d do it: get a 97-down tank, filler neck, sending unit, and fuel pump bracket from a junkyard. Then get an AEM 320 or Walbro 405 pump, and run it all straight return style. You’ll be good to go for way over 500 rwhp with those pump and tank setups.
