If you do most of the work yourself and have good local machine shops, you can probably build a 180BHP 1.9L (1926CC) with 87mm pistons, stock crank, 11.0-11.5:1 compression, custom cams and a custom dyno tune for under $4k. Stock injectors would be just fine. You don't REALLY need to worry too much about the fancy stuff MM does to lighten the valve train and crank assembly. It is primarily done to provide crazy reliability and longevity to their builds. Considering that most stock M42's will easily go 200k miles, a decent self-build should do at least that well.
I would DEFINITELY consider switching to an M44 timing case, and see about ordering a single-row timing chain setup from MM for a build, though. The stock M42 timing case was just a bad design, period. The dual-row chain is also overkill and just causes more wear & tear on the guides. The timing assembly truly is the M42's weak point, and using an M44 timing case with a single-row chain would basically eliminate the original design flaws. The M44 case also has a larger oil pump, which is a win. You would need to make a bracket to hold the crank sensor, though.
I would DEFINITELY consider switching to an M44 timing case, and see about ordering a single-row timing chain setup from MM for a build, though. The stock M42 timing case was just a bad design, period. The dual-row chain is also overkill and just causes more wear & tear on the guides. The timing assembly truly is the M42's weak point, and using an M44 timing case with a single-row chain would basically eliminate the original design flaws. The M44 case also has a larger oil pump, which is a win. You would need to make a bracket to hold the crank sensor, though.
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