http://members.ozemail.com.au/~shoeman/index.htm
Check out that site, the SR20 into a 510 has been done.
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What can this motor safely handle internally? I would be open to running some NOS if you think the motor can take it. It seems to me that the motor is pretty strong.
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I'd say 350 safely, I have seen stock engines hitting over 400HP and rumors of up to 450 or 500. The engine is hella strong, Nissan rods are already forged, so if you only intend to hit 300, you should be golden, a metal headgasket probably wouldn't be a bad idea.
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Obviously, I am a little lost. What do you guys suggest? Will an intercooler help? Bigger injectors? Greddy intake manifold? Blow-off valve? Will I need to upgrade the fuel delivery, and if so, to what extent?
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We were all lost once
Intercooler? If you don't get an aftermarket intercooler, you better not try to boost anything more than 7PSI, or you'll blow it apart. Yes, you need a blow off valve. The stock fuel system is pretty good, make sure you get a Walbro fuel pump. For 300 HP, you should be ok with your stock injectors, but they will be pretty far into their duty cycle, so upgrading wouldn't be a bad idea. The GReddy IM wouldn't be a bad idea either, not necessary, but not a bad idea.
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I figure I will push the boost up to around 12 psi (it will be a daily driver, and I can't afford to blow it up). How is this done? Can I use like a Greddy boost controller? Any cheaper options (my problem is I love technology and doo-dads, but can't afford em any more)? What else would I need to do? The car will have aftermarket exhaust, since I doubt the stock 510 stuff will do. Best header? Would upgrading to the 28 turbo help, or should I try to find a T3/4? Would I need to upgrade the injectors?
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You can safely go to 15psi on the stock hair dryer. After After 14, it's out of it's efficency range, and pointless to go higher. If you want to daily drive, get a GReddy Profec B, dollar for dollar, the best boost controller, and you can switch between hi, low and stock boost with the push of a button. Or you could get a MBC for like 20 bucks. You could upgrade to a T28 or better, a T28 ball bearing turbo, little faster spool up, and possibly go higher boost. The stock headgasket has held on somebody from NICO forums' SR on 20+psi for over 4 months.