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496 pump gas NA build

obnoxious001

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Getting started on a 496 cu in pump gas engine for a jet boat, for "Constant840" on here. Jason is operating on a tight budget, however it will be put together with a new SCAT 4340 forged 4.250" crankshaft, new SCAT 6.385" H beam rods and SRP forged pistons with a 5cc dome, should yield approximately 9.3-1 with his GM 188 casting open chamber heads. Here's where the budget part comes in, after buying the nice rotating assembly, we could not find a decent 4 bolt block that will keep him under his max budget limit, so we are going to use a 2 bolt that I have here already machined for proper marine clearance, so we should be able to get it together and tested prior to his goal of running Memorial weekend.

Whoever put the steel pipe plugs in the water jackets should be shot, need some special tools to get them out without breaking the allen wrench.

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obnoxious001

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Next steps will be to grind all the sharp edges and flash off the block so it can be washed and painted.

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djunkie

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I'll be watching this thread closely. When my 454 mag finally gives up I plan on building a 496 out of it. Thought about going bigger but I feel a reliable 500-600hp could be achieved with a 496. Would save me a lot on parts since its a standard block (which I would assume is a 4 bolt) and it has the nice rectangle port heads.
________
Ford 7Y Specifications
 
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obnoxious001

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I'll be watching this thread closely. When my 454 mag finally gives up I plan on building a 496 out of it. Thought about going bigger but I feel a reliable 500-600hp could be achieved with a 496. Would save me a lot on parts since its a standard block (which I would assume is a 4 bolt) and it has the nice rectangle port heads.

I kind of wish there was dyno money in the budget for this one, just to see what it does. I am guessing maybe 550 or a bit more. We will be running a solid flat tappet cam and a tunnel ram with headers.
 

obnoxious001

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Got the block detailed, removed all sharp edges and washed. Doesn't take that long to remove all the rough, jagged edges, and sure makes it easier to handle, and much safer to work around in the boat also.

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obnoxious001

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I also run a tap through all the head bolt threads with a speed handle prior to washing the block. The speed handle is not only "speedy", but allows me to feel if there are any bad spots that need attention.

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obnoxious001

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Made some progress today, but seemed like the phone would not quit ringing, and I had to chase parts. To make things worse, even though I had previously measure the crank, I didn't give much thought to what size bearings I needed, and after measuring a couple of bearings with the dial bore gauge zeroed to the crankshaft diameter, I realized I would need some .001" bearings to attain the proper .003" clearance instead of the .004" I was getting with the standard bearings.

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obnoxious001

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Here's a couple of the camshaft being installed. I used Isky moly cam lube on the freshly ground custom "Obnoxious" solid flat tappet cam. The handle facilitates installing the camshaft without grabbing the lubricated surfaces.

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obnoxious001

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I was able to get the crankshaft laid in the block after coating the bearings with Clevite assembly lube. I will have to continue in the morning, needed to quit for dinner (10PM)

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djunkie

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I kind of wish there was dyno money in the budget for this one, just to see what it does. I am guessing maybe 550 or a bit more. We will be running a solid flat tappet cam and a tunnel ram with headers.

Mines in an outdrive boat. So its gotta be single carb and fit under the hatch. I'd like to run a hyd roller too. I'm too lazy to check valves. :thumbsup:D
________
Yamaha dt50
 
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djunkie

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Just curious, did the crank need machining or was it good out of the box? Also if you had a choice would you go with the Scat or Eagle rotating assemblies?
________
Kenosha engine
 
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obnoxious001

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Just curious, did the crank need machining or was it good out of the box? Also if you had a choice would you go with the Scat or Eagle rotating assemblies?

The crank journals were machined very consistantly, so there was no reason to change anything. I did need to use .001" under main bearings and split the rod bearings, using half a set of .001" and half a set of standards to obtain clearances I would accept. I have assembled engines with Eagle, SCAT, CAT and RPM cranks, as well as many American cranks, personally ran an American Lunati in my own engine. Eagle maybe looks a little nicer than the SCAT, in my opinion, but all of the Chinese cranks have worked find in the engines that I have built. Some of the American companies now have some "budget" series overseas forgings that are nice (or even nicer) also, but probably cost a little more.
 

djunkie

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The crank journals were machined very consistantly, so there was no reason to change anything. I did need to use .001" under main bearings and split the rod bearings, using half a set of .001" and half a set of standards to obtain clearances I would accept. I have assembled engines with Eagle, SCAT, CAT and RPM cranks, as well as many American cranks, personally ran an American Lunati in my own engine. Eagle maybe looks a little nicer than the SCAT, in my opinion, but all of the Chinese cranks have worked find in the engines that I have built. Some of the American companies now have some "budget" series overseas forgings that are nice (or even nicer) also, but probably cost a little more.

I haven't really thought too hard over it but I have kinda looked into buying a package for the right price. Crank, rods, pistons. Problem is my motor still runs so good I hate to mess with it. But being its nearly 20 years old now I know its coming.
________
STRAWBERRY COUGH
 
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obnoxious001

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A quick shot of the Scat rods showing the measurement data I put on them with a felt pen. Since the rods were new, with no numbers, I wanted to check the rod width, besides measuring the rod bearing clearance. With the information recorded, and the rod numbers engraved into the rods, I could do the final wash.

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obnoxious001

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Shots of the assembled rods and pistons, and the block ready to accept them:

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The next several photos should come from Jason, since he was over watching the process today.
 

Constant840

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I've been a member here for over a year now and this is my first post.
So "HI" to all.
Here are a few shot I got. Unfortunately, I will not go into the detail that Barry does and I am pretty sure the photos are going to be thumbnails.
Here we go.
 

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Constant840

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...
 

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Constant840

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Timing set install...
 

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Constant840

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Cam degree.
 

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Constant840

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Checking end play in cam...
 

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Constant840

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I left as the timing cover was going on. After that, I guess would be the oil pump, windage tray, and pan. There was minimal concern over pan clearance and the new longer stroke. I'm hoping Barry didn't have to take a ball peen to the pan.
I'm looking forward to seeing some good shots in the morning!
 

obnoxious001

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So, Jason was able to get some shots that I never can do by myself. At the end of day 3 of the build, after setting the camshaft thrust to .006", I installed the cam lock plate and was able to get the timing cover on, as well as installing the oil pump, windage tray, oil filter and fuel pump. I installed the harmonic balancer, but will wait until morning to verify TDC on the balancer, and then work towards getting the heads on and the rest of the assembly.

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jrork

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Congrats Jason. You're goona be really happy with that motor. Can't wait to hear how it runs.
 

RiverDave

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I'm loving it! Keep up the great thread and pics!!

Thanks for taking the pics Jason and welcome to the board!

RD
 

obnoxious001

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Despite the fact that this is a fairly mild pump gas engine, I went ahead and took the time to verify that the piston didn't get close to the valves, and at the same time I checked to see if the pushrods that came out of his engine would work ok. You can see the soft springs, I simply verified that I could push down more than .100". there was nothing close enough to need to break out the dial indicator for this one:

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obnoxious001

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This is a solid flat tappet cam. I was fortunate enough to find some old stock solid lifters that were probably Johnsons, so perhaps they have a better chance of not having a problem. I went ahead and used some old school Isky moly lube, both on the camshaft, and the face of the lifters. As the lifters were placed in the bores, I oiled the sides. Once they were in place, I use plenty of fresh oil in the valley, and on the tops of the lifters:

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obnoxious001

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I didn't show anything about the heads, since they were assembled a couple of weeks ago and ran for 15 minutes on Jason's previous engine. I used new Manley head bolts, with pipe sealer into the block. I assembled the valve train, bolted on the intake manifold, and waited for Jason to arrive so I could show him how to adjust the valves. He should have some photos of that on his camera:



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obnoxious001

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A couple of shots of the engine tied in place ready for the trip home.

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stokerwhore

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Niiiiice! i wanna see this in the boat already:champagne:
 

RiverDave

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That last picture should be in your brochure Barry. :D

RD
 

obnoxious001

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That last picture should be in your brochure Barry. :D

RD

He was pretty darned excited to have this engine. I am supposed to lake test with him next week. I am curious how it will run in his jet boat.
 

Constant840

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So excited I forgot to grab the flywheel! I am about to head over and grab it from Barry... thought I would post a few shots from my camera from last night.
-Me adjusting valves for the first time...
-Barry readjusting my valve job... lol
-Ready to ship!
Stay tuned for install shots.
Thanks again Barry!
 

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jrork

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Congrats!!!! I bet your'e gonna be thrilled
 

Constant840

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^^^Thrilled is an understatement!
So the engine is in wired, plumbed, primed, and ready to go. I gave it a quick bump to make sure the starter engaged. No clanking, just a smooth crank. It will not be fired untill I get on the water with Barry next week for break in.
Here are a bunch of shots I snapped last night. There will be more once I get it cleaned up and then some on the water.
 

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Constant840

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By the way... River Dave, I love how I don't have to have the photos hosted in order for them to show up as full sized images as opposed to thumbnails.
 

steveo143

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Great work as usual, these threads are good and am sure appreciated by many. Barry, I have a Milodon gear drive on the way, price was to good to pass up.
 

obnoxious001

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Ok,, we broke the cam in at Puddingstone Thursday, and then decided to pull the carbs apart and rebuild them. We were able to get back to the water just before the lake closed, but only could put a couple of warm up laps on it. Today we went back to do some break-in,, get the rings seated, and make sure everything was good. While we didn't run it flat out yet, due to the lake's 35 mph rule, we did get it up to 5,000 rpm before we left.

I think it will take awhile for the smile to wear off Jason's face!
 

Constant840

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Still smiling!
Here are some shots from the cam break in.
-The other Jason and Barry looking for any leaks
-The patrol boat coming to see what all the noise was about... actually he is a friend of Barry's and gave us a thumbs up.
 

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Constant840

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The mad dash to rebuild the carbs and get back on the water.
-Barry and Jason working side by side to get me going.
Big thanks to both of these guys, it was a long afternoon.
 

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Constant840

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No shots from yesterday... but I am elated!

I can't thank Barry enough. Through out this build Barry has gone out of his way to stay well within my budget and time frame. Not only did the build come in under budget, but I am ready for the holliday weekend two days early!
Barry, you really have been a pleasure to work with. You pushed through a nagging injury and a myriad of incoming engine parts as well as phone calls to get this project done. All while taking the time to teach me some of your secrets.

Thank You!
 

stokerwhore

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thanks and i'm stoked for you on the results...although not suprised:D:thumbsup that is a clean ride you have:champagne:

...and it was nice to meet yuh -Jas
 

RiverDave

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Post the final pictures schlep rock.. All of our asses are starting to hurt from sitting on the edge of our seats.> :D

RD
 

obnoxious001

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Post the final pictures schlep rock.. All of our asses are starting to hurt from sitting on the edge of our seats.> :D

RD

He was too busy driving his boat yesterday, he didn't want to go to the trailer even when the gas gauge was showing "E".

Probably packing for the river today, but trust me he has it all shined up. I like the way he takes care of his stuff.
 

Constant840

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Had a great 4th of July!

The run down... took the boat to the river over Memorial weekend. Ran great, then collapsed a pushrod (the only part which was broght over from the last engine; budget reasons). Got replacment exhaust push rods the same day and it ran great then, pushed the timing seal (cheap Chinese, no Tiawanese, cast aluminum). Small issues to me, but man I didn't hear the end of it from the dicks I boat with.
I had a river trip planned for fathers day, but knew I couldn't afford any boating that weekend so we had some time.
Pulled the engine and gave it, the bilge, and surrounding areas a VERY thorough cleaning. Ran the engine over to Barry, fully dressed, less the engine plates. Barry popped the balancer off; more like muscled it. With a brand new OEM balancer and a brand new Scat crank the tolerances were real tight so we ran over to the machine shop and had a .001 taken out of the balancer. Installed a new timing seal with a bit of adhesive, then the freshly machined balancer... it went on real nice.
Got the engine home and cleaned one more time. Then into the boat for some driveway time. Verified timing and went throught the valves all after installing a full set of Comp push rods (donated to a good cause, I think). Everything looked good.
Got to work on the gel with some wax and the orbital, then the engine with some polish, followed by a good vacuuming. Ready for the river.
 

Constant840

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On the water Thurday afternoon...
The last one is purely gratuitous.. hehe. Thats my boy Miles.
 

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