I don't understand, why would aluminum be less reliable? There are tons of Hondas with all aluminum engines, some pushing double the horsepower per liter over a stock 5.0.
As long as you have cast iron cylinder sleeves you should be fine. Am I missing something?
As far as iron blocks go, I've heard that as long as there are no cracks and everything can be kept within tolerances an old "seasoned" block will be stronger than a new block. Has to do with the number of heat cycles it's been through.
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