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I saw lingenfelter made an "L98" with Afr heads and super ram intake, but was unsure if the block actually was originally an L98 block because the bore was 4.155".... they apparently overbored the lt1 block .100" so maybe the L98 block was a little thicker??
can you have heating problems at .040? or when do they begin in reality?
It varies from block to block. When the block is cast, the cylinders are located by a sand core. "Core shift" can result in different cylinder wall thickness. The block can be "sonic tested" for wall thickness. I wouldn't be comfortable with a bore of more than .030" over in a performance application without sonic testing first. 350 pistons ARE readily available in .080 over. Good luck, and...
I've got a .040 over L98 in my Camaro that's running just fine - 68,000 miles on the re-build & running high 12s. .060 might be iffy, but I think .040 is fine.
A .040" overbore is probably "safe", 98% of the time. Even .060" is safe 90% of the time. I would just hate to be the guy to spend the time and money, and find out the hard way, that my block was the exception to the rule. Good luck, and...