Plenum order of preference...Firstly a fully custom made and properly engineered inlet and plenum....Then:
1. RS500
2. small turbo Escort Cossie
3. big turbo Escort Cossie
4. Sierra Cossie
Yes to 16mm plenum spacer.
281kW atw with a stock 1986 YBB arrangement, but will be trying a new plenum to see if this changes the power (for fun / R&D only), but likely this is not the source of restriction at all. Also looking at a longer inlet, all custom (this is specifically for more mid range, again an interesting R&D project)
Conclusion, if you are are chasing 600hp then buy the best, else probably there is no absolute requirement...
...and on the topic of engines, then use the same order of preference too...Though what you really want is a head that is not soft and bores not too oversize...You could buy all new at cost but less risk...The alloy blocks look to be brilliant and with a longer stroke crank, the cubes go up, sounds like endless hp to be had...