to trueslayer:
i didnt know holley made a 500 cfm 4 barrel and the reason i say this is you mention secondaries but unless im mistaken 2 barrels dont have secondaries.
To greg:
for my exhaust header im going very smple since this will be my first attempt at welding any kind of manifold. im going to take a piece of 14 gauge stainles steel 3" pipe and make a log manifold with 1.75" primaries feeding into it. the turbo will be placed at the rear section of the manifold and the wastegate will go wherever i can fit it. LOL
for rods im going to go with forged steel small block v8 i-beam rods. i dont care if the ends are skinnier, i think theyll be able to handle anything i can throw at them. and for pistons, i think ill get some forged ones from that flatlanders website that was recommended to me in another thread.
as for cfm: i just used two calculations
the easy one
(RPMxCI/3456)xVE=CFM of the engine at 100% Volumetric Efficiency and for theoretical purposes only i assumed with a turbo i would achieve 150% VE, which is high but like i said id rather be overoptimistic. oh yeah i assumed a redline of only 5000 just to be safe.
i also used the best turbo calculator site ive seen at http://www.turbofast.com.au/tfcalc.html. i love this site as it has all sorts of calculators including a turbo matching calculator which is what i based my turbo size off of. its also fun to play around with the power calulator just to see the possibilities. what i did was enter all the parameters i knew with a stock 250 and then guessed the VE to get the appropriate horsepower according to the Chiltons manual i have which is pretty low around 46% VE. Then i added boost and added 5%VE for each mod i made like cam, head mods etc. but for cfm i used 100%VE engine and added 15lbs boost to see what the most id ever need would be.
hope this helps. any more questions please ask.