A 540 will take you into aftermarket block territory. There was a recent article in one of the magazines on a 502 build up. Just a set of Dart Pro 1 heads like I run, around 10-1 compression, and not an overly radical cam. It made like 670hp and around 640 ftlbs. I looked for the article and couldn't find it. I'm sure Mike will point you in the right direction.
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Todd
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