Engine Rebuild

[rppngears]

I am getting ready to rebuild the engine in my 91 mustang 5.0. Unfortunately, I was not ready to do this, I would like to have saved up enough so I could do everything I wanted to do, at the same time. But, my headgasket is going bad caused by my engine overheating when my water pump went. So I have about $1000 to spend for the parts. I was thinking of going with a rebuild kit from summit. $250 for hypauetektic pistons and $450 for the forged. Which, if either is the way to go? I don't need to desimate everything but I would like to be around 300 - 320 horses by the time I'm done.
Also, what other recomendations do you guys have for the other $500 - $750. I eventually would like a set of trick flow heads and a trick flow intake, but that won't be till next summer. Should I wait until then to go with a cam or do it while I'm rebuilding the engine. I was also considering having it bored to a 306, what are the thoughts on that?
For some background info, my car is a daily driver and must pass emissions. As of right now I have a k&N in fender air intake, dynomax cat back exhaust and timing advancement. I usually keep my engine under 5000 RPMs and I plan to keep this car for awhile, so I would like the engine to be built to last.

[95mustanggt]

At 300-320HP I don't think you're going to need the foraged pistons.

Going to a 306 will give you some power, I guess it depends on how bad your cylinder walls are.

That's about all I can offer.

[Eric4Nitrous]

I think you could make some good power with forged pistons over the others. I'd wait on the cam, for right now until you get the heads and intake. A aftermarket cam on a stock intake and headed mustang aren't gonna help you any. You can make good power with the stock cam. You can bore it to a 306 if you really wanted to..but i'd hold off on that. Use some of that money on gears, pulleys, and what not.

[jason 95gts]

I wouldn't buy anything that won't work with your future combo. I've wasted so much money buying parts for a particular combonation and say change the heads or ccam like you are going to do and have the stuff I bought 6 months ago not work properly. I would patch the old girl up and when you get your money right buy a matched kit like the ones HOLLEY, or Eddebrock sell, then you will know what you are getting. I've heard you need this and you need that, but if I did it all over again I would get a proven combination instead of a bunch of mixed match parts.

[chris91LX]

You sure you need to rebuild it? If it's just the head gasket, swap those and wait on the rebuild. Better to do it right the first time. For about $500 more you can get a 306 pro bullet from DSS or another engine shop. Look around and you can find good deals.

If you have to do it now, I'd go with forged pistons and stay with the stock cam. And don't worry, the rest of that $1k you have now will be eaten up with miscellaneous expenses you haven't thought of yet, like lifters, pushrods, gaskets, bolts, thread sealer, locktite and various parts and tools you don't know you need yet. All that little crap adds up fast.

[magicmerll]

Forged pistons are not necessary in this case. Nor is the cam. A cam will not help much with stock intake and heads.

Going 306 will cost extra $$$, and I've been told by the local machine shop that most of the time the 5.0 blocks are in good shape, and are not in need of any boring. In fact, they told me for street use, to use the stock pistons as well , as they are a quality piston and capable of handling a lot of power.

Do a nice, cheap, fresh rebuild of what you already have - rings, bearings, etc. ($300). This will give you the piece of mind that nothing is going to come apart without your permission.
Have a valve job performed on your original heads ($250). This will ensure they are flowing to the best of their potential.
If you already have headers, exhaust, etc., spend the rest of your dough on a GT-40 intake. Gears are nice, but will be more beneficial later, after you have completed the rest of the basics.

I read an article recently that talked about the stock cam being good for engines making up to 350 horsepower. Remember, the key to making power is to get as much fuel and air in, and as much exhaust out as you can. You have to have these things first.

In fact, most guys will tell you the following order is a good way to get started making some power from your Pony!

1- cat-back exhaust
2- h-pipe if you can get away it
3- headers
4- K&N or cold-air setup
5- Throttle body

Now you have - more air in, more air out. Next, get rid of the power-sucking factory parts and settings and plug in these parts-

-pulleys
-electric fan
-timing adjustments (careful! Too much timing very bad!)

Now you have - more air in and out, and no power-robbing factory parts and settings. Now you can start making serious power. But remember, you have to put that power to the ground. It's time for -

-better clutch
-better shifter
-traction-aid devices such as subframe connectors, control arms, etc.

Now more power -

-fuel pump
-intake manifold
-adjustable fuel pressure regulator
-mass air sensor
-injectors

Now you have - a lot more air in, a lot more air out, and a way to put the power to the ground. Your engine is also making power in a different (higher) RPM range, so now is a good time to consider that cam swap you wanted. Carefully read the descriptions of each cam, and decide which is best for your driving situation.

-camshaft and lifters
-performance rocker arms

Now you have - a lot more power, a lot more RPM. Time to match the rear-end gears to your engine's power band. You are now able to make power at high-rpm, so a 3.73 (manual), or 4.10 (automatic) will compliment the engines ability to rev, and still make everyday driving possible.

Finally, you have all the basic requirements of STARTING to build a fast car. This is where it gets expensive, and you have enough power to start breaking shtuff. Now it's time for the fun stuff-

-aluminum cylinder heads
-forged pistons
-balanced crank, rods, etc.
-nitrous, supercharger, etc.
-Tremec
-MORE TRACTION
-etc., etc., etc.

Good luck, you might need it!!! Hope this all helps...

-magicmerll

[chris91LX]

Oops, just noticed you have a '91, if it's the stock motor you already have forged pistons. As long as the bores and pistons are in good shape you should be able to get away with re-ringing the old pistons.