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Question, at what point do you need to fill the block with hard block?

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NEVER fill the blcok Sonic test it first before boring it, if it will be .140 or thicker after boring use it
OP, I have several 400 low deck motors, 400 with 440 crank,906 heads, single four barrel,hydraulic cam, made a little 500 HP on CA pump swill, 512 with ported big valve 906 heads and a six pak, solid roller made 612 HP at 5600 and 544 Ft. Lbs at 4500 on CA pump swill years ago, smae motor with a 4.300 stroke crank, 518 C.I., CNC ported heads and the same cam and intake made 718 HP and 745 Ft.Lbs on a Happy Studka engine dyno. My 3450 lb. car ran 10.34 at 128.6 MPH on Oregon pump gas throgh the mufflers. Same short block with M.W. intake port size Indy SR and a single 1050 Domintor on a Indy 400-3 intake manifold made 727 HP and 710 Ft. Lbs on a DTS dyno at 4300 Ft. above sea level, it has ran 9.94 at 134.8 MPH in my car with the air cleaner and muffs on The latest motor is a thick main web 400 cold weather block(Thanks AndyF )505 C.I. 4.350 bore with a 4.250 stroke Ohio Crankshaft CO. crank, Eddy RPM heads CNC ported, Mopar M1 4500 intake and a 1050 Dominator, Bullet solid roller cam with Harland Sharp 1.65 ratio rockers, it makes 687 HP and 650 Ft lbs, not ran in a car yet Too many motors and not enough cars