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Look forward to the build thread, sounds like you have a good group of friends to help out. I believe 400hp is not unreasonable on a stock block, there was someone ruining a caddy at 600hp with a stock 12v block lol Think he got a good few miles in before it went bang, if I remember correctly a piston melted. If your changing rods and pistons I think there pretty safe around 500hp, of course its normally a bad tune that kills a motor or a bad waste gate. As for welding I'm doing my own, maybe I shouldn't looking at my end results haha.

HX40 are 70lb/min compressors, turbine housing's vary from 14 to 20+ cm£ on them. 14cm will be best for lower hp <500hp or so, then 16/17cm ones will do for 550hp+. I can get brand new Wuxi ones for around the same price as the Compressor Racing ones so never a need to pay more than £400-500 for a new HX35 or 40, although CR do get some Huddersfield ones and hybrids but I'd budget that price for a Holset (or Cummins if you want to do your homework). Cast or forged won't make that much difference on the crank, if any! in terms of reliability as they are all the same material, it'