Thats what i was thinking but i didnt know the downfall as far as mpg's and egt's. But i guess when you kind of go big you shouldnt worry about those things. I was going to go with edm honed. I think thats the same as ddp.
honed and edm'd are 2 totaly diferent processes.
honing is pushing an abrasive media thru it to remove imperfections, smothand polish etc to improve flow.
edm'ing is pushing an electricly charged wire thru the metal to enlarge the holes.
pro's/cons
honeing gets you fuel flow while retaining small holes. this improves atomization, eficency etc. if not done properly, holes may plug resulting in uneaven piston crown temp, or if a verry agresive media is used it gauges the holes out rather than honeing.
edm is part of the process oem nozels are made with, but under extremly strict tolerances. alot of aftermarket edm is done with old medical instuments, and/or by poorly trained personel. it results in jaged holes, poor atimisation, some times the spray angle changes, or they push the wire to deep and it burs partway thru the oposite side.
idealy an edm'd nozel will be cleaned back up afterwards by honeing.
realisticly edm'ing doesnt realy need to be used untill getting into LARGE injectors. you can get more than 120hp worth of fuel with honeing a stock nozel and not enlarging the holes, just refining the hole, changing the sharp square edge to a smoth transition ( think velocity stack)
realistickly on the 90 vs 120 debate, how much do you want, what do you use the truck for, what turbo etc... its realy not hard with dual cp3's to suply enough fuel for 600+ hp on a 90hp nozel, and it'll run cooler in most situations. then again, a 120hp or larger will get more fuel int the cyl in a shorter period of time.......