Bone stock truck to truck year for year running down the highway same load the Cummins powered Dodge could never keep up with the 6.9-7.3 They lost speed on every hill their power band is so low in rpm's. At first I thought They where just safe drivers then I found out that was as fast as They could go at 2500rpm.

The thing you have to remember is that a cummins 12v came in a dozen diferent configurations all with the same block and internals but with diferent ip's, injectors, and turbo systems... the started in 160hp range and I think there were some intercooled versions that were just over 200... may be like 215... thats not much over a 7.3 turbo idi if any

I don't remember the numbers, but I have the intercooled version from a 3/4 Dodge in my 92. Seems to me it was 215 HP, but can be wrong on that, but around about 400 torque.

My Dodge will get the job done, but I prefer the IDI, and I HATE my Powerstroke. I will never buy another Powerstroke as long as I live. The IDI has just as much potential for power as the Cummins or the Powerstroke, it would be much easier and cheaper to get the power you want out of the engine you have than to put something else in it. I wouldn't put a PowerJoke in one of my older trucks if it was a bolt-in conversion.

From '89-'94 they were ALL 160hp/400 ft. lbs.
The difference was the NON-intercooled '89-'91 had 18cm turbo housings and they spooled-up fast. They were QUICKER.
The intercooled '91.5-'93 had 21 cm turbo housings and are NOT quick.
The '94s had wastegate turbos and are VERY QUICK.
From'95-on they just got progressively more powerful and faster.

I have run my '91.5 *****-to-the-wall for extended periods in third gear on VERY steep grades at the governor which is about 3100 rpm. Most guys think runing at the governor is bad so they won't do it. That's why they run at 2500 instead. The problem is going to 4th. gear PUTS you too LOW in the powerband and you can't power out of third and into 4th. without losing the power band.
I don't know here this 2500 rpm red-line notion I always hear came from but the lowest governed speed they ever had was 3100-3200 rpm. The newer the truck is the higher the governor is set.

The guys drag racing them usually throw-out the governor and just let their foot govern the RPM, they run up into the 5000 range routinely for a few seconds at a time.

I have to agree with you in the PowerStroke being my LAST choice out of my trucks, in fact I think it's going to be traded off/sold to someone who doesn't know any better.
I have to disagree that the IDI has the power POTENTIAL of the Cummins. That's just not so.
Obviously you can go to extremes and build a very powerful IDI but the Cummins is capable of rdiculous amounts of power that obviously serve no purpose in the REAL world.
It's also easier, and most likely cheaper, to beat the power out put of an IDI with a mechanical Cummins.
Both will do anything that needs done so it boils down to personal prefernce.

I STILL would NOT swap a PowerStroke into ANYTHING!
In fact if I could get away with it where I live (and I can) if a PS went bad I'd swap-in a turbo IDI.

No mater where You set Your high rpm peak torque is at 1500rpm auto or 1600rpm man and falls off like a rock so at 2500 it's not making any power more rpm's don't help. You've got to get more air and fuel to it. Same for the 6.9's they just don't fall off as bad.

If I tried to pull a hil at 1600 rpm, where the peak torque is, I'd be going backwards in short order.
The horse power is much higher in the RPM range and that's what keeps you moving up the hill.
I can tell you for SURE that you don't want to be trying to pull a hill at 1600 RPM in your IDI OR Cummins. Torque gets you going and HP keeps you going.

so what do ya think would be the best hp/torque numbers to shoot for when you do a build up? keep in mind I dont wana break anything. I'm thinking 300/550... but then I wonder if I'll start breaking stuff at those numbers

How much breaks depends on what you are doing with it and how you drive it.

I load heavy and drive normal/fast.
I would never even think about reving the engine and dropping the clutch or speed shifting.

I drive like I am driving a truck.

U joints and drive shafts don't last long.
I have split one transfer case in half and twisted off the rear axle yoke before.

14 years old at 111,000 miles your truck may be 40 years old before the engine needs a rebuild.