block damage can be welded in some circumstances. do you have any pictures of the damage?
and as been said, the block is cast not forged. FYI, no blocks are forged.
can't help you friend, wish i could. you might want to go talk to the service manager at ford dealership and ask him/her where they get the heads from their modular V8's machined (they require a very low ra because of the use of MLS head gaskets). you might get lucky and find a dealership that...
actually, your torque is going to do nothing but go up. the stock exhaust is so restrictive when you replace it full boost will come on dramatically sooner.
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