1. good brand for bigger radiator and if hoses come with?
2. should we also have the plenum spacer ported and polished or is there a upgraded version?
3. shortcuts, read somewhere that the stock intake system could be modified somehow, i dont think were trying to go cheap but shortcuts and free power cant be beat also.
4. good brands for all these parts we need and if im forgeting something would make for some more power since we got the heads off already without doing cams, rods, cranks or pistons.

1. Griffin. Best RADs out there.
2. Plenum spacer? If you're talking about the IMRC plates, you should remove them or rig them bitchs to stay open.
3. If you guys already polished and ported the intake, why replace?
4. FRPP!

But seriously, No need to go PI if you have plans to port and polish the heads n such. Plus its a work truck. If he wants cheap HP and good MPG, find a Gen II Mark VIII. The 4.6 DOHC in those are rated at 280hp and 300tq.

Here is my main question... Its a truck, why is he valuing HP over TQ? Does he plan on some top speed runs or pulling equipment?