Blown Injected 540 BBC build

[Wheeler]

Looking Good! Have a merry Christmas. :beer

 

[FLATMVN]

Well got around to doing a little more work on the new mill today. As I posted earlier there has to be some alterations made to the set up. Here are some pics of the first issue that I am dealing with. As you can see I have a small alignment issue with the top and bottom blower belt pulley's.

When I originally started this project I asked several blower builders if the front dimensions of the case were the same between a 671 and a 1071, I was told that they were. Apparently not, a 1071 is 5/8 of an inch longer than a 671. Maybe there was some misunderstanding as to what I was asking but I thought I explained it very well.

To resolve the issue BDS is going to build me a set back adapter to move the blower back 3/4 of an inch. The reason we are doing a 3/4" inch set back is that is the minimum that can be done so that the bolt spacing works out. This will not hurt the air flow into the manifold. The extra 1/8"will also give me some extra clearance between my belt and my water lines on the water pump. As you can see the belt was really close to the lines.

 

[FLATMVN]

One thing that did work out for me was the stainless hard lines. Switching from a short deck block to a tall deck and then the extra height of the raised exhaust ports on the aluminum head I thought I would have to make new ones. All I had to do was adjust the bends some and they fit perfect.

 

[RiverDave]

I'm loving the hardlines!! Keep it coming!

RD

 

[FLATMVN]

Well I finally resolved the issue with moving the supercharger back. Ended up pulling the intake off. I was very careful doing this so that I would not get any gasket material in the new engine. I got pretty lucky most of the gaskets stayed glued to the intake and not the heads. I ended up taking the supercharger and the intake to BDS and they re-drilled the bolt pattern to move the supercharger back 3/4". Also had them machine the recess for the o-ring to seal the supercharger to the manifold eliminating the need for a gasket so that we could just re-drill the bolt pattern to move the supercharger back. I milled the opening in the manifold back 3/4" to open it up so that the supercharger would match up and there would be no obstruction. Here is a pic of the intake all machine work done and ready to go back on.

 

[FLATMVN]

Well I did a little work on the new mill the last couple of days. I mocked up the intake and supercharger and intake to make sure that everything is going to fit and align correctly. Also mounted the new oil filter/cooler 90* adapter.

Here is the new adapter and how it looks on the engine.

 

[FLATMVN]

Here is a couple of pics showing the alignment of the supercharger pulley's corrected. Also I installed the offset for the MAG to check for fit, making sure that it does not bottom out on the oil pump drive. it goes all the way down with no gaskets, so when gaskets are installed there should be plenty of clearance.

 

[jrork]

I've got nuthin to say other than breathtaking!!!! Can't wait till I have my own Barry motor (though it'll be half what you're assembling) of my own.

Keep up the incredible work/craftsmanship................john

 

[FLATMVN]

Thanks John, Barry and I were talking about your motor a couple of weeks ago, it should be a nice piece for your application. A 502 is not a bad deal, should run respectable.

 

[FLATMVN]

Had some free time the last couple of days and got the new bullet in the boat finely.
Snapped a couple of pics of the new bullet in the boat.

First is the tight fit of the fuel pump, but there is just enough room to get it all in there.

From the other side.

 

[FLATMVN]

Here is couple of it from the sides in the boat.

 

[.boatpoor]

Hey Louis, whats goin on with the oil cooler? Is that a small one down by the filter, you may want to think about useing a bigger one. Motor looks great in the boat, don"t work it tio hard I"d like to see it in Sept.:thumbsup

 

[obnoxious001]

Not even running yet and you are already in trouble with the law!

Also, the exhaust backpressure is going to be a bitch with those plates on it!

 

[FLATMVN]

Hey Louis, whats goin on with the oil cooler? Is that a small one down by the filter, you may want to think about useing a bigger one. Motor looks great in the boat, don"t work it tio hard I"d like to see it in Sept.:thumbsup

No worries Steve, Barry told me that I can't tear it up. Obviously he don't know me very well.

You will get to see it run in Sept, I am going to get it good and broken in for you. Speaking of Sept you make reservation yet, a couple of us are already booked the dates are the 11-18.

 

[FLATMVN]

Not even running yet and you are already in trouble with the law!

Also, the exhaust backpressure is going to be a bitch with those plates on it!

You know me I am one of those shady characters. Always bucking the system and doing things I shouldn't be doing. They let me out on a weekend pass so I could work on the boat, but they said I had to have a guard with me at all times.

You told me it would make tons of Horsepower, you don't think it will make enough to blow them off.

I was thinking of cutting some relief holes in them do you think that will work.

 

[Hallett]

Looking great Louis she looks mean as hell. i bet you can't wait to get
it on the water looks like she is close.:thumbsup

 

[FLATMVN]

Yes it is close but I still have a few Diamonds and Pearls to buy her before she will let me take her for a ride. If everything goes right should be in a few weeks.

 

[RiverDave]

Well I did a little work on the new mill the last couple of days. I mocked up the intake and supercharger and intake to make sure that everything is going to fit and align correctly. Also mounted the new oil filter/cooler 90* adapter.

Here is the new adapter and how it looks on the engine.

What is the reasoning behind putting the oil filter on a 90?

And where is the maiden voyage gonna be? In parker?

RD

 

[obnoxious001]

What is the reasoning behind putting the oil filter on a 90?

And where is the maiden voyage gonna be? In parker?

RD

I will let Louis answer about the filter, my guess would be clearance.

Dollars to donuts says the first test will be at Blythe.

 

[jrork]

Here is couple of it from the sides in the boat.

So F'n Sick!!!!! That looks badass Louis...... Can't wait to hear how it runs.

 

[Flat Broke]

What is the reasoning behind putting the oil filter on a 90?

And where is the maiden voyage gonna be? In parker?

RD

Dave,

For cleaner rigging it's nice to have the filter in the stock location, but clearance is usually a problem. To make matters worse, a sandwich style adapter used to allow plubming an oil cooler adds length to the filter and usually puts the fittings coming out at an angle that requires some kind of compromise on the fitting selection of the hose.

I've never used a setup like this, but I've been looking for something similar for when my mill goes into the Spectra. The fitting placement will allow the lines to naturally fall right down along the stringer, and the 90* filter relocation negates the need for a remote filter mount. The only downside I see is slightly messier filter changes compared to a vetical mount, but I'd take that compromise for the compactness of the plumbing and filter location.

A question for FLTMVN, what diameter are the ports the AN fittings thread into? And this is for a MK IV block right?

Thanks,
Chris

 

[FLATMVN]

Dave,

For cleaner rigging it's nice to have the filter in the stock location, but clearance is usually a problem. To make matters worse, a sandwich style adapter used to allow plubming an oil cooler adds length to the filter and usually puts the fittings coming out at an angle that requires some kind of compromise on the fitting selection of the hose.

I've never used a setup like this, but I've been looking for something similar for when my mill goes into the Spectra. The fitting placement will allow the lines to naturally fall right down along the stringer, and the 90* filter relocation negates the need for a remote filter mount. The only downside I see is slightly messier filter changes compared to a vetical mount, but I'd take that compromise for the compactness of the plumbing and filter location.

A question for FLTMVN, what diameter are the ports the AN fittings thread into? And this is for a MK IV block right?

Thanks,
Chris

Hey Chris,

You are correct on the reasoning for the 90* mount to simplify the oil line routing and it makes the flow of the oils smoother also, I will get some pics of it installed and plumbed in the boat. Also I wanted to use a 2 quart oil filter and with the engine setting low in the boat there wasn't enough clearance to hang the filter straight down with a standard sandwich adapter, I would not have been able to remove the filter.

As for the size of the fittings they are -10 AN .

 

[FLATMVN]

Well guy's if finely had some time to work on the little monster that has been on the back burner for a few months. A couple of my buddies came out to the shop today and we went to work on the 540 in the Rush. Well at 3:20pm this afternoon she came to life and was breathing fire. The new motor sounds great. Being new to manual fuel injection it took me a couple tries to get it to fire. First I had to remember that you have to have the cap on the kill switch for it to run. Once we put that on it would fire right up, but it would not stay running. Well now to the newbie part, I figured out that the engine will run longer if you pull the fuel shutoff cable out so that the fuel will actually flow to the injector hat. Now that I know how to make it run I think it is going to be one nasty piece when it hits the water. Still have a few things to work out on it before it is ready for a water test that will be in a couple of weeks, as I will be leaving Wed to fly to Atlanta to see my friend that lives back there. We are going to go to the Nascar night race at Bristol Motor Speedway.

 

[FLATMVN]

OK guy's and girls here is the video of the new mill running.
Might take it out and run it later today.

http://gallery.me.com/flatmvn#100016

 

[obnoxious001]

OK guy's and girls here is the video of the new mill running.
Might take it out and run it later today.

YouTube

Link's not working?

 

[jrork]

Damn Louis......you're killing us with the tease. Let's see it~~~

 

[FLATMVN]

Link's not working?

It works for me. I don't know what you are doing.

 

[jrork]

Barry...I'm coming back down with my motor!!! I want one of those!!!

Louis, that boat and motor are just badass!!!! Congrats:champagne::champagne:

 

[obnoxious001]

It works for me. I don't know what you are doing.

Well, it works now that you called me on the phone and I explained that you had linked to your You Tube home page, and then you fixed it.

Can't fool me!

 

[RVRDAD]

Sounds Great! Looks AWESOME, wear a helmet!!!!!

 

[wrighton]

Louis, Did you get any more play time with the boat and motor?

 

[jrork]

Louis, Did you get any more play time with the boat and motor?

Come on Louis, updates man, we need updates. Did you drop it off with Barry to work a bit more magic and clean up after that lil dizzy dealio???

 

[FLATMVN]

No workie on yet Barry is a little backed up, good deal for him. I have lots of time. Don't worry I will bring it out to kick your ass one of these days.

 

[jrork]

Don't worry I will bring it out to kick your ass one of these days.

May be holdin you to that there Cupcake!!!

:worthless_1_:

 

[Hallett]

Louis what's going on with your motor ?
you going to parker this weekend .

 

[FLATMVN]

Hey Bob, Motor is just sitting in the boat. Waiting for Barry to get freed up so I can get it to him.

No did not make it to Parker this weekend.

 

[steveo143]

Are you still planning on using that stainless exhaust that you have?

 

[FLATMVN]

So far there is still a plan. Don't know how long it will take. You are still first on the list if I don't.

 

[vdcruiser]

Whatever happened to this deal, did you run it?

 

[obnoxious001]

Whatever happened to this deal, did you run it?

He ran it for a short time until the bronze distributor gear on the mag offset that he supplied failed. He has been very busy, but plans to pull the engine and have me take it apart and clean it all up rather than risking damage from the bronze bits floating around inside the engine.

 

[vdcruiser]

Gotcha, I followed this build from way back and was curious how the Rush would run with that engine.

 

[FLATMVN]

Barry and I both have been busy. But don't worry we will get it fixed and throw some numbers out when it gets going. Thanks for the intrest.

 

[sdpm]

While your at it, you might want to recheck the depth of the dist gear as well. Actually measure it. I saw that your offset didn't have an adjustable slip collar.

 

[obnoxious001]

While your at it, you might want to recheck the depth of the dist gear as well. Actually measure it. I saw that your offset didn't have an adjustable slip collar.

I haven't seen the offset in person, so will have him bring it with the engine. The offset was purchased after the engine left here.

 

[FLATMVN]

ROUND 2

 

[FLATMVN]

Well as most of you know I had a drive gear failure on the offset. Well Barry and I finally found the time to get together and take the engine apart. We determined that the reason the gear failed was poor engagement of the cam and drive gear. When I installed the offset what I thought was proper engagement was off by about 3/8". The Indy manifold that I have was suppose to be machined for the use of a standard deck distributor application on a tall deck block assembly. Well it was not machined that way for some unknown reason. So now it will get an adjustable offset so that we can set it where we want it and hopefully will not have this issue again.

So today we stripped the whole engine down and replacing the Rod and Main bearings. We disassembled it carefully looking for particles of bronze from the gear. Everything was looking like it had never happened until we got to the Mains, pulled the main caps and there were obvious signs of the debris from the gear going through the mains. So it came all apart and we cleaned and fully prepped the block to remove all debris. Will be installing new bearings and making it like brand new again.

I was snapping some pics while Barry was assembling the engine and I took some shots of the bearing damage will get them up as soon as I can.

 

[vdcruiser]

Very good, keep us posted. Do you have any details on the hull, like strut angle and placement, V-Drive gears, prop size/make, etc.,etc. ?

 

[FLATMVN]

Well the hull is a Rush Performance, 20' GN. Weight 750#, I have not measured the stut angle myself but It should be about 7*, and the placement was all done when the boat left Grier Rush's shop I have never measured any of these as the boat was rigged when I bought it. V-drive is a 10* Casale, 29% gear as of now but probably going to a 40 to 45% gear. Prop is a 11 1/2-14 risght now that may change also.

 

[vdcruiser]

Thanks, yea that motor will probably want more gear and prop. What about prop shaft size ?

 

[FLATMVN]

1 1/8 prop shaft. Boat was rigged for drag racing originaly, I changed some of the rigging to be more GN style.