Tim, I asked Steve the same thing a couple of weeks ago when I dropped off an LS3 block with him. He recommended that I go with a 4.155" bore in a dry sleeved block. 4.185" is the max you can go with a dry sleeve, and I believe 4.210" is the largest you can go with a wet sleeve. I'm going with a 4.155" bore dry sleeve for a grand total of 447ish cubes. If you really want to hit the magic "454" number and still be able to clean the cylinders up later with an over-bore, you'll have to go with the wet sleeves, which require you to run Evan's Coolant and Water Wetter. Additionally, you'll need a set of Cometic's head gaskets, etc. After my experience with wet sleeves, I wouldn't take another chance with them.
As far as piston rock, and rod angles. I wouldn't worry too much. When I took my 454LS apart there was a little bit of wear on the piston coating, but nothing terrible. I like to air on the side of caution and after looking at everything I'm still retaining my 4.125" crank with a 6.125" rod.
Matt
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