I have a nice documented low mile Fury with 360. I plan on building a 440 but want to make the right decisions:
I want a strong 440 with 450 - 475 hp as goal Any core 440 can do that in stock form, with modern performance machining, and a moderate hydraulic cam, and decent exhaust.
It should be able to lay rubber (I just purchased 3.23, 9 1/4 rearend with sure grip) See above.
I worry about a motor that is over bored and at risk of cracking (how much over is ok with sleeves)? Boring is done to provide a perfectly round and straight bore. It restores the wear surface. It's not done to make an engine bigger, nor does it really affect the ability of the block to transfer heat to the coolant, unless it is taken too far. I would limit any over bore to +.030 at max. There are plenty of std bore or running 440s that don't need to go beyond .030 over.
I would like it to be a strong sounding motor but not overly loud so my wife complains and hence will not travel in the car Good dual exhaust need not be loud, and cam choice determines if headers are warranted or not. Plan to run manifolds and cam accordingly, and she'll be happy.
I heard before 1972 is important? Forged Crank, etc. The only thing forged vs cast will do for you is be cheaper to internally balance. There is no other boon to using a forged, and many salesmen think because it's aforged crank it's worth a lot, and cast is worthless. That difference in pricing is normally more than the difference in cost to internally balance. Forged came in everything up to '72, and in some HD applications in cars and trucks up until '78. Cast ran '72-'78.
What are best heads / design 904, 906, etc. Personally I like 346/452s. But really once they are fully machined with new valves, a 5 angle valve job, etc etc, they are pretty close to the same. Use whatever is on the core engine. With no porting but fit with performance valves and a 5 angle valve job any head will flow enough for your hp levels.
I have never built a motor before and appreciate all suggestions
Do I need a new transmission 727 now, but is 440 different? RBs share the bellhousing pattern with the B wedges. Your A (small block) 727 will not interchange. You'll need a big block transmission too. However the driveshaft and shifter linkage will be the same. You will also need the correct kickdown linkage for the RB (440).
What is good stall in torque converter 2200 rpm? The convertor stall should be lower than your intended highway cruise rpm, and should match your cam. IMO, a factory high stall unit of around 1800 will be fine. Also - the heavier the car, the higher the stall speed IN THAT CAR.