I am debating on whether or not to scrap my 410 and build a 428. The 428 block is already bored .40. Which setup has the better potential the 410 or 428. By potential I mean horsepower, torque and rpm's. Also, if I decide to build the 428, which supplier has the best selection of high compression pistons for a 428. What compression pistons is everyone else running. The engine will be used for truck pulling. The 410 would usually run about 6500 rpm's.
You had better get the cylinder walls on that 428 sonic checked. The few extra cubes you might gain won't help you if the pistons go through the cylinder wall. You might be okay at .040 but that should be getting very thin. I don't know of many people running .060 on their 428s and having good luck. TRW (Speed Pro) makes good forged pitons at a reasonable price. They are available in a couple different compression ratios. Above that you have the expensive racing pistons. BTW, you are only talking a couple ten foot pounds of torque difference. The 428 bore allows you to run 1.73 exhaust valves.
Congrats on even aquiring a 410, they're not as plentiful as they used to be . Essentially the 410 is a 428 in a 390 block.Same crank and rods just different bore(4.05 as opposed to 4.13) I've had several 428's and I wont bore one past .030. The cylinder walls in these blocks are thin from the factory. I work for a foundry and we have actually X-rayed and sonic tested some of these blocks and core shift causes some very thin walls. If you want my 2 cents, I would bore the 410 block (probably a c6ae or c7ae casting) .030 over. this will give you 417cu.(nominally), and all the benefits of the 428's stroke. If money is no object, a set of Ross or Venolia(if you can find them) pistons would be awesome. I use Ross pistons in my Pro street 428. Compression is 10.6-1. If your on a budget it's hard to beat a set of TRW's or KB's.
Basically the castings settled wrong and you ended up with cylinders with very thick walls on one side and very thin on the other. Somebody else can give a much better description of how this actually happened but I think I threw out the most important part.