I want to hit 250 whp on my 91's 1.6 with FM's gt2560r and all supporting hardware. 120k miles odometer. This is a street car, not a daily though. Will I run into hole-in-block syndrome at that power level on a non built motor? If so, how high can these engines push it before forged internals is necessary to keep the engine intact? I don't want to spent thousands to wind up with a bomb, that's no fun. Thanks (edit: spelling)

 

200wtq is considered very safe.

200wtq at 7k is 260whp. Let some professional tune your car. Make sure you don't have boost creep and if so, port your wastegate as good as possible before sending it to a reputable tuner.
It can be a lot of fun with a stock engine and 250whp at the very top end is likely to be reliable, even with a 1.6

 

Maybe not hole-in-the-block territory, but approaching dammit-bent-rod territory with stock rods. I recently finished a 2871 churbo 1.8 with stock rods and - after the break-in - on the first semi-aggressive pull I got an instant bent rod. So be careful.

 

Easy to hit 240+tq with a 71mm compressor wheel He really needs to find a good tuner