Now my first question is, how hard would it be to just swap the engine directly into my truck? Doesn't it have something to do with the engine being offset in the 2003 instead of centered like the newer models?
Non-starter. Completely different engine. It would bolt in and to your trans, after that it's a no-go for a variety of reasons.
Second question, if I'm building the 03 block with 09 parts, what parts will I need to accommodate for them? I'll need a intake manifold adapter plate and I will need a car style timing cover to clear the intake and relocate the a/c & alternator right? I read a post where 1 of the a/c lines can be reused and bent into place but the other needs to be remade. I used to be an a/c tech apprentice so I can probably do that myself.
Car style timing cover will just cause you to rearrange your accessory drive for no reason because the manifold doesn't clear the temp sensor in the block. It would only help with making room for the TB, honestly if you're handy fabricating you can move the A/C compressor and alternator out of the way; people been doing this to 3rd gens for literal YEARS to put 6.1 intakes on (or you can just buy the kit). You don't need an intake manifold adapter plate to put the eagle intake on eagle heads, you need SPACERS to lift the manifold clear of the aforementioned temp sensor boss.
I will be using basically the entire top end from the 09, and rebuilding the block, but I don't know what kind of pistons and cam and stuff would compliment these new parts. I am also considering a slight bore in the cylinders so I can make sure they're all symmetrical and fresh surfaces. I am also leaning towards a cat and O2 delete so I can straight pipe out to the rear tires, so once again, I want a cam to compliment the pipes so it sounds decent and not stupid haha
That's where you need to talk to the vendor/builders like Inertia, HHP, MMX, etc. If you're using eagle heads, you'll need to decide what CR you want, then get pistons to match. If you're thinking boost down the road then everything needs to be forged and you don't want too high a static CR.
I also want to port the manifold and heads, but I guess it's not necessary, since it will all be matching 2009 parts, and all the ports are the same sizes and shape right? Should I also take the exhaust manifolds from the aspen? Will they even fit since my engine is off center? or should i spend a couple bucks on a set of headers that will once again complement the cam and straight pipe exhaust?
The Aspen manifolds will work just fine.
I wouldn't mind building this engine with boost as a potential option in the future without having to rebuild again. So that means I should go with forged rods and piston? Forged crank too?
Yes, see comment above. You can either go with a full aftermarket kit (then you could stroke it) or use a stock 6.1 crank (they are forged) with a set of matched rods & pistons.
I'll be replacing all the springs in the in the valves and replacing all the lifters as well. I heard the srt lifters have bigger and better bearings and fit, is this true and should I go out of my way to get them?
I think the last time I went looking at lifters, all non-MDS lifters are the same part number, at least 6.1 to Hellcat application wise.
Basically, for anyone who has the time and you were my shoes, what would you do from start to finish? What would be the best way to use this 2009 aspen in my 03 ram?
Convert to 2005 PCM/harness. Grab heads and intake manifold. Bracket the necessary accessories out of the way. Procure matching cam (I've got a KRC 210 waiting to go in). Put it all together and tune it. Honestly this is what is in the process of happening to my truck lol. My problem is, whenever I decide it's a good time to to tear it down, I need the truck lol.
And since I'll have an extra 5.7 block laying around, I could rebuild that and drop it in my 05 4.7 Durango couldn't I? Or should I just use the Durango as a backup transmission and rebuild that tranny for when I eventually blow up the one in my truck? Haha I could fix up the Durango, but it's pretty rusted out and needs a lot of body work compared to my ram.
You COULD, but then you have to do all the conversions to it (not drop in, plug and play)
Should I also take the computer from the 09 aspen? Or will it not work the same since it's a Chrysler SUV instead of a dodge truck? Either way I plan on picking up a tuner for it and will get a custom tune done for deletes and cam to take advantage of the upgrades.
No. You can't integrate a next gen CAN bus PCM into your PCI bus vehicle.
Speaking of deletes, I will have to get a egr delete and an MDS delete as well right? Or is it vvt delete? It's so confusing lol but that requires plugs for the holes the solenoids go in right? Then I just leave the plugs dangling.
If you convert to 05 PCM yes you will need EGR deleted from the tune. MDS is not a factor, neither is VVT.
Now that I am talking about wiring, will I be able to use my 03 harness on the 09 parts? Can I get away with, snipping those parts off at the scrapyard and soldering them in to my harness? Or is the 03 harness missing leads that I would need? Since I'm deleting a ton of stuff out anyways, it shouldn't matter because my block doesn't have any of those newer system.
Resounding no.
I should also mention that found another 5.7 from a 2013 ram, complete but torn apart for 700. Similar kms but newer. The difference is the aspen 09 5.7 is still installed in the vehicle and I can start it to make sure it runs and sounds good. 2013 came out of a ram when the timing chain broke. He got the engine swapped under warranty and was going to use it in another project, but never got around to it. Since it's torn apart I could inspect it for damages, and if I did go that route, what would I specifically be looking for? What sounds like the better deal? 2013 for $300 less than the 2009?
The 2009 aspen is being sold by a mechanic who bought it off a customer. He replaced the engine himself a few years ago and did all the maintenance up to this point, but after an accident the owner didn't want to fix it and sold it to them. He is also throwing in the aspen rads and fans, harnesses and all accessories, basically everything under the hood he can get rid of lol. Which reminds me that I also want to do the e-fan conversion in my truck and take some drain off my crank. I'll have to find out if I can use the fan or rad from the aspen if I choose that path.
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Absolutely doesn't matter, because you cannot use the whole engine in your vehicle. So whichever one you wanna steal the heads and intake from, go for it.
