2. Rod Shop
Pontiac's stock cast-iron connecting rod is quite reliable when it's operated within its original parameters, and if properly reconditioned, it most likely remains adequate for a modern moderate-rpm performance build. But after considering the fact that even the newest rods are now more than 30 years old, and that proper reconditioning includes finding eight useable cores, upgrading each with 7/16-inch ARP bolts, and then resizing the caps, it's no wonder aftermarket forged-steel connecting rods are such an attractive option.
A number of companies offer forged 4340-steel connecting rods, which are capable of enduring much higher output levels than the type of build discussed here, and that can be reflected in the price. However, Pacific Performance Racing (PPR) in San Pedro, California, and SD Performance in Chilliwack, British Columbia, sell the Tomahawk; Butler Performance in Leoma, Tennessee, sells the RPM; and Kauffman Racing Equipment, in Glenmont, Ohio, sells the Pro-Warrior. These are all affordable options designed for more moderate combinations.
These connecting rods are 5140-steel I-beam forgings that are considered a direct replacement for the stock cast-iron units, and a complete set costs around $250, or about as much as it would to recondition a set of stockers. They come fitted with 7/16-inch ARP bolts and are ready to handle at least 500 horsepower.
3. Stroke Me
I know, I know. You had your heart set on a 455, but you can't seem to find one locally. Well, you don't actually need a Pontiac 455 to attain that displacement.
Virtually all of the major Pontiac builders can supply you with an aftermarket long-stroke crankshaft kit that will turn a 400 into a 455, and possibly larger. Such kits also include forged 4340-steel H-beam connecting rods, specific forged-aluminum pistons, and all of the piston rings and bearings required for a complete rebuild. The near-$2,000 price tag may not be within your budget, however.
Butler Performance provides an affordable solution for the budget-minded build. Using a cast-steel long-stroke crankshaft, forged 5140-steel I-beam connecting rods, and Sealed Power forged-aluminum pistons, BP's kit (shown here) will take a typical 400ci to at least 455 for $1,350. The assembly is also computer-balanced for ease of installation. A forged 4340-steel H-beam rod option adds about $125 to the kit.
Kauffman Racing Equipment offers a similar budget-minded long-stroke crankshaft kit that includes a cast-steel crank, forged 4340-steel H-beam connecting rods, and Keith Black forged-aluminum pistons. It also includes all necessary rings and bearings, is balanced, and comes ready for installation for $1,410.
While a long-stroke kit can soak up a good portion of your available budget, don't forget that it includes everything shown here, which is virtually all you need for a complete short-block rebuild and can easily set you on course toward 400-plus horsepower with as-cast D-port cylinder heads.
4. Camshaft Query
Camshaft technology has come a long way over the years and roller valvetrain components are commonplace in modern vehicles. Only recently has a wide array of retrofit roller camshaft and lifter kits been made available for the Pontiac V-8, but the technology comes at a price. The possible performance gain a hydraulic roller camshaft might possess over a similar flat-tappet doesn't always outweigh the added cost in a budget-minded rebuild.
Hydraulic flat-tappet camshafts remain a popular hobbyist choice for a number of reasons. They not only provide strong performance at an affordable cost, they operate quietly and require little maintenance after initial break-in, and an upgrade to a more radical grind isn't an overly expensive proposition.
Some critical high-pressure additives have been removed from modern-spec oil and that can cause flat-tappet camshaft failure, but said failure can be averted by following the manufacturer's recommended break-in procedure and stated instructions for normal-operation, as well as using top-quality oil that contains the necessary level of additive.
Expect to pay around $200 for a high-quality camshaft and lifter set like that shown here, while hydraulic roller cams generally start at approximately $600.