2008 V6: You make a LOT of good points, and believe it or not, I have looked, HARD, at doing a Windsor conversion. Ex-NASCAR engines are not unheard of in AIX, and even in AI, there are more than a couple of 336, 347, and 351 Windsor motors running around the track. I even have an engine builder in my Rolodex, who did the motor in the CMC car after we popped one.
That said, when it comes to the actual numbers, the Windsor engine would have to provide some SERIOUS benefits to justify the cost. As I'm starting from scratch with that platform, there are a LOT of expensive bits that would have to go into the equation. Aftermarket ECU, fuel injection and spark control will run roughly $4500, including tuning. Given my focus on endurance racing, the extra fuel efficiency gained from EFI over a carb becomes a factor. The gains may not be much, but even one extra lap per fuel load can be the difference between a win and a loss, and EFI is positively more efficient than a carb. Next up is the biggest known weakness with the Windsor engine: the block. On the stock castings, the #2 main web is, ahem, prone to splitting the block into a pair of V-4 engines, and it gets awfully expensive when that happens. The solution is to start with an aftermarket block, like the World Man-O-War or the FRPP Boss block. That's a tick over 3K, plus finish machining. Add in the rotating assembly, decent heads, high-RPM valvetrain, engineer the FEAD stuff and then all the small parts, and by my math, you wind up between $10K and $11K in the engine and accessories. Yes, you could do it on the cheap, trying to "trick" an Explorer ECU into managing a race motor, and running factory injection bits, but the hard-parts savings will rapidly be eaten up in the tuning and fiddling about. You might save $2K by going that route, but you'd be left with a lash-up full of potential compromises. It's one thing if you already have a 302-based injected motor to begin with, but starting from scratch is a bit more expensive.
Re-bopping the 4.6 3V is the second option. We know the factory bottom end is plenty stout if you keep it N/A and don't spin the piss out of it. I honestly don't want to rev this thing much past 6500-6800RPM, and asking the engine to deliver 350-360 to the wheels isn't all THAT stressful. If I freshened up the stroker motor, it's a combo that is known to deliver 390+ HP, and I would have to de-tune it to get it within my desired parameters. On the plus side, stroker motors in general tend to be torquey things, but I don't know if I can actually pull 40HP out of the thing without going to a restrictor plate of some sort, which sort of negates the advantage over the Coyote. If, on the other hand, I transplanted to the top end of the engine onto my stock bottom end, I think I would be pretty close to being in the HP/TQ range that I'm targeting. The real question is what the cost on those parts would be, and for that, as well as details of exactly what the parts are, I'm just patiently waiting.
Finally, the last option, the Coyote. Cost of the crate motor PLUS the ECU kit, PLUS the alternator, PLUS the power steering pump bracket runs roughly what just the Windsor block and EFI setup would cost. If you were to buy new for the 3V, the cost of CNC heads, cams, phaser kits, intake manifold, T-body, and hardware is bumping up to 50% of the cost of a complete new engine. With the Coyote, I can get machined restrictor bungs for $50/ea, so I could pretty easily buy 4-5 of them and get the dyno tuning done in one shot.
Yes, it is heavier and more massive than either the 3V or Windsor motors, but not by all THAT much, and unless there are other compelling factors, I would rather have an understressed stock-level engine than one that's wound up as tight as Rosie O'Donnel with a plate glass window between her and the dessert buffet...
Really, for me, it's coming down to a pure matter of dollars and cents. If it'll cost me more than 50% of the cost of a Coyote to pull a measly 35HP more out of my 3V, I'll probably just hold off and do the swap. That would also allow me to pull the restrictor and ballast, swap tunes, and run in ST2 (8.0:1 power/weight), OR pull the ABS harness on the car and run AI at an 8.5:1 power/weight. That gives me some options.
Again, I did look at the Windsor, but to do one right, the cost is well north of what I'm willing to spend. If the used 3V stuff comes in at the right price, that's a contender, but at the moment, I'm leaning towards the Coyote just for the sake of ease. THAT would be an off-season project, and would also depend on exactly how much work I can book between now and then as well.