Thank you for the responses!
I am not trying to replicate the K-code specs or parts, just wanted to add some horse power to the car knowing that the 225 was gross and most likely overstated. There is no intent to use it other than street. However I do like the gains of the newer components, but the engine is still stock (outside of replacement belts, hoses and spark plug wires.
I guess I would like to have the valve job on the heads (keep the same size valves), some porting, possibly go to the Shelby/Cobra intake, if I do not stay the iron. I will have the block looked at and either honed or .20 as needed.
The iron manifold is barely adequate to the cam upgrade you propose.
For the flat top pistons with relief valves, is there one mfg better than the other? Also should I be looking at ones related for 9.5:1 CR?
Compression ratio involves the heads as well as the pistons. For the record, when I say "flat top", I mean the stock 60's item, which always had valve reliefs. There were, IIRC, some truly flat-top pistons in the 80's, but a) they suck, and b) they won't fit your 289 anyway.
I will get the rods reconditioned if still good, or is there a better option for that?
No. The stock rods, with proper reconditioning and modern bolts, can easily sustain 7000 rpm.
If I go with the Cobra/Shelby Alum intake, is the Autolite 4100 1.08 still adequate?
With a stock C3AZ-V cam, yes. But your whole point was to upgrade the cam, so no, your C9OZ-C cam will strangle on that 480 cfm 1.08. The 500 Summit won't be much better. I do like the Summit, but with the cam upgrade a 600 is mandatory.
My friend rebuilds carbs, so he can help me dial it in as needed. Would this or Weiand Stealth cause and clearance issues with the hood and carb?
I've never seen it as a problem.
Also based on that would I be looking for one of the Cams mentioned above or does this set up change that?
The C9OZ-C is an excellent, all-around street cam, easily capable of providing you 320 hp.
And finally I was looking at using the exhaust manifolds (vs headers) but using a set of hipo manifolds into either the GT exhaust setup (with mufflers and resonators) or the Arvinode exhaust system.
I have the HP manifolds, put them back on when I tired of the usual noise, heat, loose bolts, and pavement scraping of the headers. They feed into stock 66 GT exhaust. Car runs (and sounds) very well.
I have tried to upload pics of the car, but I can only get the pics down to 30kb. I will try again to reduce them further.
Strange, this photo is 209kb, uploads perfectly: