Powering a Hallett 240

[yuppie]

Currently have a 496HO with a little over 500 hours, may need the top end rebuilt soonish.

Been toying with the idea of dropping in a new or lightly used motor with more power. I've got a Bravo 1X outdrive and just the standard Bennett trim tabs.

If I wanted to keep the Bravo 1X on there, what motors should I be looking at to make this thing scoot?

Thinking about Merc's 500, 525, 520...

Would I need to put full hydraulic dual-ram steering and new tabs on there?

 

[NicPaus]

Steering and a XR or better drive. I have the same power and thought about buying a 525.

 

[Runs2rch]

You won't even need to think about a top end on a 496HO. It will go 1k-1500hrs if cared for. Then rebuild the complete package.

XR or better with more power in a heavier single like the 240 is.

 

[yuppie]

You won't even need to think about a top end on a 496HO. It will go 1k-1500hrs if cared for. Then rebuild the complete package.

XR or better with more power in a heavier single like the 240 is.

That's good to hear. Maybe I just leave it alone for a while... but another 10-15MPH would be nice!

 

[1fastsedan]

I would just rebuild the existing block you have and beef up your Bravo 1. You can buy a blower for the extra needed MPH now and then transfer that over to your new build. Max Machine Worx can make your existing drive stout and then you could add steering to complete the package.

 

[yuppie]

I would just rebuild the existing block you have and beef up your Bravo 1. You can buy a blower for the extra needed MPH now and then transfer that over to your new build. Max Machine Worx can make your existing drive stout and then you could add steering to complete the package.

Is it possible to add a blower to the 496HO? I've heard they can get funky when adding on modifications.

 

[1fastsedan]

Whipple Superchargers

Explore the legacy of Whipple Superchargers, a family-owned and operated powerhouse since 1987. Founded by the innovative Art Whipple in Fresno, CA, our journey from racing circuits to leading supercharger technology reflects a commitment to excellence. Experience the Whipple difference in drag...

whipplesuperchargers.com

Cast pistons aren't ideal for blown applications, but it sounds like many have had success with this set up.

 

[UltraLucky]

General rule of thumb, 1 mph gain = 15 to 20 additional HP needed. Your going to double the cost of your boat searching for 10 to 15 mph gain. That's after adding steering and drive upgrades needed for an additional 200 to 300hp. Not saying it's not worth it or fun going there, but have a realistic budget.

 

[J DUNN]

My 240 had monsterous tabs custom built by Carson from original rigging in 95'. It never had hydraulic steering and I never felt it needed it. It ran 900HP on a Bravo for most of it's life until I upgraded to the BMax in 2018ish.

 

[85RiverRAT]

These guys are 496 guru's. https://www.raylarengineering.com/496mag-marine-performance-parts.html

The engines you mentioned at the top of the thread are obsolete with exception to the 520.

500's/525's will be found used as pull outs and will need a rebuild, or build something to mimic those motors. Finding a 500EFI, or 525EFI new in crate is not likely possible.

 

[yuppie]

These guys are 496 guru's. https://www.raylarengineering.com/496mag-marine-performance-parts.html

The engines you mentioned at the top of the thread are obsolete with exception to the 520.

500's/525's will be found used as pull outs and will need a rebuild, or build something to mimic those motors. Finding a 500EFI, or 525EFI new in crate is not likely possible.

I wonder how fast a 520 w/ XR drive would be able to go... I like that it's a really new motor but it may not make that big of a difference at the end of the day.

 

[Runs2rch]

I wonder how fast a 520 w/ XR drive would be able to go... I like that it's a really new motor but it may not make that big of a difference at the end of the day.

Mid 70's.

 

[yuppie]

Mid 70's.

Yeah, seems like a whole lot of work for 10mph gain…

 

[Runs2rch]

Yeah, seems like a whole lot of work for 10mph gain…

Exactly.

 

[85RiverRAT]

I wonder how fast a 520 w/ XR drive would be able to go... I like that it's a really new motor but it may not make that big of a difference at the end of the day.

Mid 70's.

This. Same ballpark and comments as over in the other thread. Marginal improvement.


Run and maintain what you have until it breaks, and then replace everything to bring back the turn-key reliability. Performance will be about the same without some big changes and big $$,$$$.$$.

 

[Livewire Fabworks]

520 low 70's, and don't forget the 520, discontinued 540, and 565 are all DTS systems so you are looking at a lot of wiring and upgrades to your current systems.

 

[hallett21]

Merc 600

 

[yuppie]

Here is what I found from one dealer...

Bravo XR: $11.5K - new

575: $20K 100hrs

525EFI: $35K - new

500EFI: $15K 168hrs

I wonder if I could run the 500EFI with my current Bravo1X without hydraulic steering and still be safe...

 

[yuppie]

Instead of swapping the motor, it may be better to try some different props.

I've got a 23P on my 496HO, Bravo 1X drive. Would this setup be able to handle a 26P or should I just go up to 24P or 25P?

Hoping to get a little more top-end speed, I'm fine losing a little acceleration.

 

[Done-it-again]

The rev 23 is a good prop as it give it stern lift. Bravo 26 is too big. You can try a labbed 25 but its pricey.

 

[JFMFG]

You won't even need to think about a top end on a 496HO. It will go 1k-1500hrs if cared for. Then rebuild the complete package.

XR or better with more power in a heavier single like the 240 is.

That’s what I thought I threw a rod out the block at 340 hours on my 496

 

[2FORCEFULL]

 

[2FORCEFULL]

thought this was interesting, same 525 efi ,26p prop, 26' cheetah deck boat...

I was able to run a 29p labbed prop... but,.. scary results... so I only ran it once...

 

[farmo83]

I would sell your 496 and buy a BBC based motor. Parts will be much more available and many more people will work on them. As has been stated in stock form they run forever but as far as upgrades go IMO there are better options out there.



Drives to me seem to be a lottery pick. A friend of mine ran a bravo around on a 26 daytona with 1100 hp for 10 years and never had a problem, I’ve also known bravo’s that let go on 525s. It’s all about how they are driven, cared for and how heavy the boat they are on is. Having said that my boat came with a bravo 1 and an old blue 500 carb motor and I never had a problem with it. Ran that way for 25 years until I redid the power train.



As far as steering goes I’m a fan of it but there a lots of boats out there without it. You run the risk of wearing out your gimbal ring with out which isn’t cheap to replace. Nor is steering cheap either so it’s really how much you want to spend.

 

[yuppie]

Yeah, you're pushing that 26p really well, but you're also on a 525EFI whereas I'm on a 496HO, so I'm not sure it matches up entirely.

I'm thinking I should be safe enough with a 25P, but I'll ask some shops in town what they think.

I would sell your 496 and buy a BBC based motor. Parts will be much more available and many more people will work on them. As has been stated in stock form they run forever but as far as upgrades go IMO there are better options out there.



Drives to me seem to be a lottery pick. A friend of mine ran a bravo around on a 26 daytona with 1100 hp for 10 years and never had a problem, I’ve also known bravo’s that let go on 525s. It’s all about how they are driven, cared for and how heavy the boat they are on is. Having said that my boat came with a bravo 1 and an old blue 500 carb motor and I never had a problem with it. Ran that way for 25 years until I redid the power train.



As far as steering goes I’m a fan of it but there a lots of boats out there without it. You run the risk of wearing out your gimbal ring with out which isn’t cheap to replace. Nor is steering cheap either so it’s really how much you want to spend.

I would love to and I've been able to find one or two rebuilt 525EFI's out there, it's just a matter of costs at this point. I've heard the same thing about drives, seems to come down to how it's driven but with a 525 on there, I feel like the Bravo 1X's days are numbered. Add on hydraulic steering and trim tabs and yeah, you're pretty much doubling the price of the entire boat!

There is nothing wrong with the motor I have, it starts up every time! I'll try to mess around with different pitch props to get a little more top end.

A new motor might be a few seasons down the road.

thought this was interesting, same 525 efi ,26p prop, 26' cheetah deck boat...

I was able to run a 29p labbed prop... but,.. scary results... so I only ran it once...

Scary results? Assuming you mean the walk... Maybe these would solve that issue?

 

[02HoWaRd26]

Baby steps. If you’re planning to keep long enough to enjoy the mods, I’d start by taking out the inversion plates from between the manifold and riser. Cost 50$ for new gaskets but I’ve never needed to replace them on all the boats I’ve done, and it’s very worth it believe it or not.
Then find your starting place. Me I’d do steering if the motor and drive are all good. You can do full power or assist, but at that point my opinion will always say go for the best once vs spending money twice and do full power from helm back.
Next I’d be looking for a good used even if buy separately XR upper and lower.
Than if you’re still feeling mopowa is needed you have everything done in preparation of that.

 

[BUDMAN]

my opinion is this. It doesn’t seem like you’re real happy with the boat you purchased. ( not too many 240s wtob available) Clean the boat up, fix the minor things that bug you and maybe update a couple things that buyers are looking for. Sell it and spend a little more money on something else with bigger power. Your honesty not going to get the speed numbers you’re wanting out of a heavy Hallett. It’s doable, but at what cost. Counting the purchase price of the boat you bought and what you’re willing to spend on repower and the upgrades that go along with it, you could have found something with big power and run at the speeds you’re wanting. Don’t know what kind of boating experience you have but high power boats is a whole different animal to handle in the water. I can name a handful of people I would trust to ride on their boat that has big power. Just my .02 worth. You should have no problem selling current 240. Hope you can find what you’re looking for and enjoy the boating experience we all love.

 

[Done-it-again]

my opinion is this. It doesn’t seem like you’re real happy with the boat you purchased. ( not too many 240s wtob available) Clean the boat up, fix the minor things that bug you and maybe update a couple things that buyers are looking for. Sell it and spend a little more money on something else with bigger power. Your honesty not going to get the speed numbers you’re wanting out of a heavy Hallett. It’s doable, but at what cost. Counting the purchase price of the boat you bought and what you’re willing to spend on repower and the upgrades that go along with it, you could have found something with big power and run at the speeds you’re wanting. Don’t know what kind of boating experience you have but high power boats is a whole different animal to handle in the water. I can name a handful of people I would trust to ride on their boat that has big power. Just my .02 worth. You should have no problem selling current 240. Hope you can find what you’re looking for and enjoy the boating experience we all love.

2nd this..... If needing more speed and keeping somewhat the same room, go with a Shockwave Termor. The 240 will need more power to get moving the same speed than most boats its size.

 

[yuppie]

my opinion is this. It doesn’t seem like you’re real happy with the boat you purchased. ( not too many 240s wtob available) Clean the boat up, fix the minor things that bug you and maybe update a couple things that buyers are looking for. Sell it and spend a little more money on something else with bigger power. Your honesty not going to get the speed numbers you’re wanting out of a heavy Hallett. It’s doable, but at what cost. Counting the purchase price of the boat you bought and what you’re willing to spend on repower and the upgrades that go along with it, you could have found something with big power and run at the speeds you’re wanting. Don’t know what kind of boating experience you have but high power boats is a whole different animal to handle in the water. I can name a handful of people I would trust to ride on their boat that has big power. Just my .02 worth. You should have no problem selling current 240. Hope you can find what you’re looking for and enjoy the boating experience we all love.

I'm happy when I'm on the water! I just can't leave well enough alone

https://imgur.com/0jtFDNv

Nah, I really appreciate this boat more and more every time I take it out. Definitely going to update the some cosmetic stuff and it'll be good with me for at least a few seasons while I learn more of the ins and outs.

I'll probably try a couple different props and see what that does. Appreciate your $0.02, really want to take a ride on your 255 someday soon!

2nd this..... If needing more speed and keeping somewhat the same room, go with a Shockwave Termor. The 240 will need more power to get moving the same speed than most boats its size.

Hmm, if I'm really going to get into the go-fast stuff, I think this new Trick 23' widebody would be a fun ride!

I'll be paying attention to how these come out in the next few months.

 

[NicPaus]

You running a rev 23? I have 1 and a few others. It almost pulls the same top speed as my labbed bravo 26. But has better low and midrange. I heard the hallets like the rev props better than bravo. I have been looking for a bravo 25 but no luck. Should of bought 1 new 2 years ago. Now they went up 200.

 

[yuppie]

You running a rev 23? I have 1 and a few others. It almost pulls the same top speed as my labbed bravo 26. But has better low and midrange. I heard the hallets like the rev props better than bravo. I have been looking for a bravo 25 but no luck. Should of bought 1 new 2 years ago. Now they went up 200.

Not sure if it's a Rev, there are no branding marks on the outside of it at all, just a serial number on the inside.

 

[NicPaus]

Not sure if it's a Rev, there are no branding marks on the outside of it at all, just a serial number on the inside.

Post a pic. It's easy to tell the difference between a bravo and rev.

 

[BUDMAN]

I'm happy when I'm on the water! I just can't leave well enough alone

https://imgur.com/0jtFDNv

Nah, I really appreciate this boat more and more every time I take it out. Definitely going to update the some cosmetic stuff and it'll be good with me for at least a few seasons while I learn more of the ins and outs.

I'll probably try a couple different props and see what that does. Appreciate your $0.02, really want to take a ride on your 255 someday soon!


Hmm, if I'm really going to get into the go-fast stuff, I think this new Trick 23' widebody would be a fun ride!

I'll be paying attention to how these come out in the next few months.

You’re welcome to take a ride anytime I’m out.

 

[02HoWaRd26]

I'm happy when I'm on the water! I just can't leave well enough alone

https://imgur.com/0jtFDNv

Nah, I really appreciate this boat more and more every time I take it out. Definitely going to update the some cosmetic stuff and it'll be good with me for at least a few seasons while I learn more of the ins and outs.

I'll probably try a couple different props and see what that does. Appreciate your $0.02, really want to take a ride on your 255 someday soon!


Hmm, if I'm really going to get into the go-fast stuff, I think this new Trick 23' widebody would be a fun ride!

I'll be paying attention to how these come out in the next few months.

on that video! But that Trick is a dime piece.

 

[Ballyhoo]

I'm happy when I'm on the water! I just can't leave well enough alone

https://imgur.com/0jtFDNv

Nah, I really appreciate this boat more and more every time I take it out. Definitely going to update the some cosmetic stuff and it'll be good with me for at least a few seasons while I learn more of the ins and outs.

I'll probably try a couple different props and see what that does. Appreciate your $0.02, really want to take a ride on your 255 someday soon!


Hmm, if I'm really going to get into the go-fast stuff, I think this new Trick 23' widebody would be a fun ride!

I'll be paying attention to how these come out in the next few months.

You have a classic boat that will never go out of style.

The best upgrade you could do right now, would be full hydraulic steering all the way to the helm.

It would take more than just dropping in a higher HP engine. You would need to upgrade the drive and get big tabs. Unless its your forever boat and you have a bunch of $$$, just keep that 496.

My 24 Schiada is similar to your Hallett.

My original Merc 502 lost a valve in 2004. Before that the boat would run high 60s max. I had it rebuilt by Brummett Marine and its now a 540. On its best day its about a 74mph rig. After all these years its getting tired and its now 70mph max- somedays 65/66. Its due for another rebuild.

In 2006 I added full hydraulic steering.

The boat currently has small Bennett tabs that really don't do anything. I will likely get it rebuilt in similar fashion with similar HP. I will upgrade my drive before that to an XR. I am also seriously consider some much bigger tabs to help the ride at 60mph plus.

When you are talking HP and speeds, if you want to go 70mph, you need a rig that will go 80mph. My engine builder told me this- 10mph over what you want. You don't want to be banging max RPMs all day long.

The best prop for my current setup is a 24P. You would likely have similar results with a 24P.

 

[yuppie]

You have a classic boat that will never go out or style.

The best upgrade you could do right now, would be full hydraulic steering all the way to the helm.

It would be a lot more than just dropping in a higher HP engine. You would need to upgrade y the drive and get big tabs. Unless its your forever boat and you have a bunch of $$$, just keep that 496.

My 24 Schiada is similar to your Hallett.

My original Merc 502 lost a valve in 2004. Before that the boat would run high 60s max. I had it rebuilt by Brummett Marine and its now a 540. On its best day its about a 74mph rig. After all these years its getting tired and its now 70mph max- somedays 65/66. Its due for another rebuild.

In 2006 I added full hydraulic steering.

The boat currently has small Bennett tabs that really don't do anything. I will likely get it rebuilt in similar fashion with similar HP. I will upgrade my drive before that to an XR. I am also seriously consider some much bogger tabs to help the ride at 60mph plus.

When you are talking HP and speeds, if you want to go 70mph, you need a rig that will go 80mph. My engine builder told me this- 10mph over that what you want. You are just not going to be banging mx RPMs all day long.

The best prop for my current setup is a 24P. You would likely have similar results with a 24P.

Thanks for the advice, you've got an awesome boat! Seems like I'll need time to tell me if it's worth throwing on steering, a new drive and new tabs for a bigger motor.

 

[MK1MOD0]

Just a couple things I would add. I would NOT add a supercharger to a 496 period. I have a good buddy that did. He didn’t beat on the boat at all and drove it very conservatively. We were cruising down the river and the motor just shut of.... when we popped the hatch, the lower pulley and the end of the crank were in the bottom of the bilge. It snapped off completely! Cast cranks and blowers are not a good combo. As for the drive, send it to MMW. It will be stronger than an XR for less cash When finished.