I am considering putting on a set of undersized pulleys, is any one running these and if so were there any adverse affects associated with them? Currently motor is stock other than k/n filter, I will be installing jba headers this weekend , will there be any interference with stock plug wires i was told i will need new ones with a 45 degree boot? What other bolt-on mods will give the most bang for the buck. thanks.

 

supercharger is bolt on hehe. get some plug wire protecters so you dont melt the wires. the pulleys i feel are not really worth it some have said that it causes there headlights to dim when the motor is just idleing. the headers will give noticable gains but you will also want to get the rest of the exhaust done to otherwise it will just be a bottle neck. I went 3inch from the Y pipe out the back with flowmaster muffler. new truck efi intake and throttle body would also be a good bolt on as well. a cam would also be good but wouldnt until you have the rest done because the cam should be tailored to what you have for best performance.

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You shouldn't have any problem with the plug wires, although the 45 degree boots will give you a little extra room. I agree with KB that you should look into some wire protectors unless you are running top of the line wires. I have Taylor SpiroPro wires on my 5.0 with JBA headers and I have yet to see any ill affect.
As far as other bolt ons, again I have to agree with KB (great minds think alike?) that helping your bronc breath better should be at the top of your list. Not too much on the exhaust side though, if you go too big you could lose a good deal of your low end torque. 3" like KB if you go single, 2.5" if you go dual like me.
You say in your post that you have a K&N filter. Is it a drop in factory compatible filter, or did you get an Aircharger system? The drop in filter will flow much better than a factory filter, but the Aircharger opens things up and lets your 5.0 gulp some air.
A good aftermarket ignition system and coil with performance wires, rotor, & cap will give you noticeable gains as well. Purchasing an aftermarket MAF for your 96 is a worthwhile investment.
Underdrive pulleys offer little gain compared to the overall pain in the behind that they are.
If you want examples of how the stuff looks on a 96 5.0, there are pictures in my gallery. There are more/better pictures on my website.

Hope this helps.