You go to a billet engine block. The factory design can only be reinforced so many ways but it is always a compromise. A ground-up billet design for the application is the proper (albeit expensive) way to do it reliably.
Do you really think those 1500+ horsepower Hondas and 2500+ horsepower Nissan GTR's are doing it on factory blocks? Absolutely not.
This is how you get to a custom billet block capable of huge power according to Bullet Race Engineering:
1. Start with an OEM block. Scan it to establish baseline dimensions
2. Improve the design to make it more rigid, more durable, more reliable
3. Load a 130 kilogram block of 6061 aluminium billet into the 4-axis CNC mill
4. Remove most of the material until it looks like a Honda B-series
5. Keep removing metal
6. Now you have a block suitable for all Honda B-series applications that is better in every way and only requires minimal modifications to replace the original block
7. Throw the original block in the skip with the swarf - it's still worth a few dollars as scrap metal
What you see there will hold 1700+ horsepower and will run you $7500+ dollars. That may sound like a lot but it is actually affordable. For one, you have the Honda volume so several of these will sell plus it being a four-cylinder requires less material and makes for an easier design.
A Nissan GTR VR38DETT 4.0 liter 2500+ hp capable billet engine block can run over $25k.
How much power do you want to reliably make and what do you want to spend? That is what it comes down to.
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