I started a thread, three weeks ago, on Speed Talk, regarding wall thickness and what might be to thin as well as, at what point it will cause hp lose:
https://www.speed-talk.com/forum/viewtopic.php?f=1&t=64800I know that TODAY, it's commonly accepted, that you shouldn't bore a block more than .030 and the main reason seems to be that, it's because you will loose hp, if you do. I started the thread on ST because there is a wide variety of engine builders of all common American V8's. I also, checked what wet sleeve tractors use.
In my day, we didn't have sonic testing and everyone bored, at least .060 and many 1/8" but, I don't recall anyone splitting a cylinder wall because of it. So, in those days, if you bored a 352, FE 1/8", you had a basic .107 cylinder wall. My best friend had a 303 Olds, he bore 1/8" to 324 but, 56 Olds heads, then put in a 280 duration, Herbert roller cam and mounted a 4-71 blower, w/2 AFB's and drove it for 8 years and 2 years before that, w/o the 4-71 but, 4 x 2's instead.
My own opinion is that you should have a min wall thickness of .120 but I found some wet sleeves at .115. Those are even, all the way around and not thicker in some/most areas. But, my main interest was at what thickness do you start loosing hp. There was no answer to that! I was hoping to find a few builders that said "I freshen this engine, X number of times and dyno it, each time. When it got to .X over, it lost power and I had to replace the block".
The diameter and length of the unsupported cyl wall make a difference, too but, there wasn't any input on anything that showed lose of hp.
Sorry, JC-427Stroker for taking this a little OT but, with that much power per ci, it does seem some what relevant to Geoff's engine.
I know the 351C had a problem splitting blocks but, don't remember them says they lost hp until they found a split.