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Hi All,
I'm thinking of rebuilding a 79 302. It has been rebuilt by the previous owner many years ago and bored to 40 ths over i was told. The compression is low on a few cylinders. Hence the need for rebuilding again. I really don't want to spend a lot of money on it. So, once i hone it can i use 60 ths rings with some filing of the ends of the rings to get the proper ring gap without boring?
Not really because the pistons and rings are sized to be used as a set. If your bores are that far out that they need more oversize and you only take the rings out that far, then the smaller piston/ ring grooves will not provide proper support for the ring. My guess is this would result in rings breaking way prematurely or wearing badly.
Find a '94 or newer 302, a later Mustang or Explorer/Mounty 302. These are roller motors. You may have to fiddle with the front engine accessories, but either the serpentine will adapt to your truck, or your old stuff can be made to work on them. You can swap a carb intake and an old style distributor in there, and if you have to, put your old manifolds on them. An honest 200 HP, more if you want.