5 liter MOPAR

RustyRatRod said
From .030 to .040 is a .010 difference. I know you knew that already but bear with me. Maybe you didn't think of it like this. Another .010 is "only" .005" from half bore. .005 difference in the radius. Got that part? Now, if a .005 difference in the radius of the bore on a block was "too much" and made the block "weak" as you're eluding to, then that block needs to go in the garbage if it ever needs a .030 over bore. Stop and think about what you're saying. You're saying that 5/1000 of ONE INCH is the breaking point.

There's just no way that's true.

100% true but the problem can be thin spots in parts of the bore where that little bit MAY make a difference.

If you are on the edge already with thin bores that extra .005 may be the straw that breaks the camels back.

These castings are wildly inconsistent. I do not like running on the edge (one of the few times I don’t like doing that) if you are trying to make any kind of power or you are going to tow with it...stuff like that.

IMO it’s always better to use the smallest overbore possible to clean and straighten up the bores. Thicker cylinder walls have much better ring seal and ring seal is power.