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I am going to be changing my setup by going with AFR heads, a Comp 220/224 115+2 XE-R cam, and a Vortech T-Trim supercharger. I am thinking that if I am going to have my car all apart I need to at least consider forging the bottom end at the same time.
I assume that properly tuned with about 9psi I should be able to get 600ish rwhp out of this combination. The reality of my situation is that I live at high altitude (7000 feet) and loose about 25% of my horsepower. This turns the awesome 600 rwhp into about 450 or so rwhp.
At a rwhp level of 450 to 500 is it really necessary to go with aftermarket forged rods or could I just use the stock rods with ARP bolts? Are there any "budget" LS1 specific 6.100" or 6.125" rods available?
I would change the rods. Chris at ECS did my engine and we went with Diamond Pistons and Callies Rods. The only parts that are "stock" on my engine are the LS1 heads and the LS1 crankshaft (the stock crank is very strong).
Remember that a forged bottom end is not really a higher performance engine; it's more of a stronger engine for FI applications.
You sound pretty close on your RWHP esitmates. With the ECS ATI kit and the Lingenfelter blower cam and Kooks headers, my car made 574 at the tires. Don't forget about the fuel system and the clutch if the car is a six speed.