piston questions

i think you're picking fly **** out of pepper here.

you're not building a street/strip motor, you're not doing burnouts, you're not hunting 10th's or trying to eek out MPG.

the stock magnum bottom end has proven itself both capable and durable enough for your application, why not go with that? one of the benefits of the stock mag pistons is the design: the top ring land is nowhere near the crown and the bottom is fully clear of the pin boss. on those 405's the top is clipped by the valve relief and the bottom shares with the pin boss. not for me, so siree, not on a build like this.

you're worried to death about the CR, yet you only want to run 87. i'd stop fretting about it. also, the newer motors were built a bit better than the older stuff with better materials, better machining, tighter tolernces and more attention to detail.

i think @TT5.9mag gave some solid advice. screw it together stock, bump the cam up one size with a custom grind (don't buy no junk off the shelf) get a good dual plane manifold and roll.

My point was from a financial standpoint. He's had one failure. If he's going to BUY pistons (he may not) but if he IS, it's nonsense not to put a couple hundred more toward it and get forged. ...and that's from a cheapskate.
Alot of the point of this thread is info seeking, "bench racing", basically fundamental discussion. I haven't turned a wrench on it yet.
Like rusty has said I have had 1 failure already. I know the reasons why, and no, I haven't told the whole story on what lead up to that failure.
But I DON'T want a 2nd. Call me gun shy, whatever. But I ain't the only person messing with these engines, and can't be the only one wondering "what if I do THIS" or what if I do "THAT" and I hope someone else out there is getting some good out of what's being discussed here. What's wrong with that.

Probably not unlike many, I want what I want out of it at the end of the day/ a long lasting torquey engine that doesn't burn oil, has more power than stock, gets the best mpg it can for what it is .. while I correct the factors that causes the first rebuild on this block to not work out. I don't want bragging rights for either cheapness or "get I spent the most of anyone on one of these".... I want bang for the buck, I know I have some leftovers from the years of working on cars and trucks, parts bought previously for projects that didn't happen for whatever reason, and wondering if I can put some of them to use to save a few bucks this time around.... If not then so be it ... But I'd rather ask someone who may have tried what I'm wonder about.... I'm sure somebody has.
Once I get the rough combo in place I know there will be tweaking and tuning.... I can deal with that.