^^^Now I am wondering what are the absolute upper limits (RPM, boost, total peak power output) of our BLOCK (given that it is aluminum alloy), even with the very strongest, and most
precisely balanced, internals/rotating assembly available on the planet at this time.
Block is probably fine for what power levels we would see...up to the new GT25-550. Things start to get dicey when you run above 30 psi from what I saw with Issac and DHM, yeah? The deck does seem to slowly deform over time when run above ~400+ HP with poor fuel distribution. Adding 4 injector aux fueling seems to be the best option. The gap between the cylinders close together and ovals out at them. Then, at some point it would blow out and you would lose the cylinder wall. So, could put shim in there like puma speed sells for pretty cheap as insurance.
LINK TO SHIM (pics too). Alternatively, these guys sell a thing like this: [video]http://pwnallperformance.com/new-1-6l-ecoboost-bare-block-with-cylinder-support-system-from-cncwerx.html[/video]
SpeedPer6manc3 ran a stroked 2.3L block till they blew a hole out the side at 35 psi and ~700 HP. That is around 300+ HP/L. I remember Deadhook nuking stock 1.6L blocks at around 420 ish at maybe like 32 (?) psi of boost, but it wasn't my car and I don't remember the exact number...but that is around ~260 HP/L. Most of it is all thermal stress from what I understand.
Now, the pistons seems to crack or melt somewhere above ~375+ HP, and you will seem to spin one of the stock bearings in the ~400-420+ HP range. Haven't seen a thrown rod, but there's a first for everything. So, you could probably max out most reasonable turbos with a built rotating assembly, headstuds, and adding a shim into the stock block with good 4 port aux fueling, or just get a nice short block from those guys above.