AH64ID

I am not sure on the HG issues, they both have the same bolt pattern and surface area... So it shouldn't be any more or less prone to HG failure.

Seems like a lot of work and in the end it won't pass emissions anywhere (stupid reason, but its coming whether you like it or not).. No other changes in a 06 or early 07 than the 08-09's.. would be much easier/cheaper to get one of the 5.9's and bolt a 6.7 short block to it, as that's the only part that would work off a 6.7 truck (well the injectors too).

I too have heard over 500hp go 5".. thou have also heard of guys dynoing over 600 on stock, and only gaining a few ponies with an exhaust swap. Stock intake is good for 450+.

5.9 parts
head (04.5-07)
wiring harness

6.7 parts
short block
CP3
injectors/nozzles
rail pressure sensor (will give you more pressure with 5.9 tuning)

Aftermarket
Cam
Turbo
Tuning
Valve Springs
Intake Horn (or stock 5.9)
Exhaust Manifold (or stock 5.9)
Turbo


Thats just a quick list, I am sure there are many other parts/pieces that would be needed... Again, best to do this on a 5.9 truck....
IMHO a 03-04 ECM and wiring would be the best. No 3rd event, better economy. But any 5.9 ECM is good.