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1969 Road Runner Project, Part IVMajor Muscle in the Engine Compartment From the April, 2000 issue of Mopar Muscle By Jerry Pitt Photography by Jerry Pitt, Ken Lazzeri
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Grunt, Oomph, Twist. That's real power. Power is what Mopars are known for. At the root of that power, the key to wheel-lifting launches and asphalt-rippling burnouts is torque. Torque is also what defined 1960s muscle cars. While today’s four-valve, DOHC, fuel-injected vehicles offer performance, you don’t hear much about torque--nor do you feel it. Today’s high-revving, light-switch-for-power engines are super-efficient, clean burning, and high-revving. But they lack pin-you-in-your-seat power that forces you hang on when the pedal hits the floor. Heck, in some cases, a torque monster doesn’t require even moderate accelerator pedal travel. Perhaps that is why when Holley chose to build ten project cars--one from each decade of the company’s existence--there was no question that the automotive selection for the decade beginning in 1960 would be a big-block Mopar. Holley Performance Products and its brands including Lunati, Hooker, Earls, Holley Superchargers, Weiand, and Nitrous Oxide Systems all have an affinity with large cubic inch, V8 muscle. The choice to go with a Mopar for a decade as important as the 1960s is significant commentary regarding whose muscle cars made the most power consistently. Torque is the back-to-basics commentary--but how would one add a twist of today's trends. When Holley approached us about their Project Roadrunner, they asked who we thought should engineer the Mopar-specific powertrain combination. Certainly, the answers could range from a crate Wedge or Hemi from Mopar Performance Parts, but that might reduce the potential content of Holley brands in the engine assembly. With the goal of exhibiting Holley's brands, we suggested that Indy Cylinder Head be the engine builder. With their loyalty to the Mopar community--displayed in their long list of products made specifically for Mopars--as well as their far-reaching reputation, we knew that Indy would be the place to go. Holley agreed--in fact they had already come to the same conclusion prior to our suggestion. Holley would look to Indy Cylinder Head for the gospel according to Mopar big-block power. In the early discussions with Ken Lazzeri of Indy Cylinder Head, it was apparent that there were several options--maybe a mid 400ci low-block stroker or perhaps a huge displacement 440-based RB. The intended use is what helped to make the final decision of which displacement big-block Mopar to build. The Holley Performance Products Project Roadrunner would be a street car. Sure, it might do a quarter-mile once in a while, but primary use would be cruising--even long distance Hot Rod-style Power Touring. This Roadrunner would be four-speed shifted backed up by the stoutest Hemi A833 possible, yet produce enough torque that you could basically leave it in Third all the time. Lazzeri told us, "We have built many 500ci pump gas engines and they were capable of 600 to 610 lb-ft of torque and nearly equal horsepower--in street compression. Additional displacement was the key to building a torque monster." Ken also knew that a bit more displacement may pull down the horsepower figure, but the torque would rise exponentially. "When you try to create a torque monster on purpose, the equation is fairly simple--moderately high velocity heads and a relatively small camshaft. You sacrifice peak horsepower." Sacrifice horsepower? "Heresy," you say. Ken continues, "The reality is that building high-torque engines puts horsepower on hold. Our goal was torque first." Remember, horsepower is a function of torque. The polar moment of inertia happens sooner when the fulcrum favors the power source rather than the object to be moved. You get more torque with a bigger stroke and the benefit of that higher displacement is that torque is anticipated. When you couple it with a mild camshaft, moderate compression, and street hardware, you get the maximum reliability, very smooth running operation, and in our case, over 575hp. For those of you who are counting, that's still more than one horsepower per cubic inch. That, with a mere 9.5:1 compression--it'll run on any gasoline in the world. Best of all, while premium components are used, the engine internals are far from exotic. To gain the torque figures that would test transmission and the abilities of driveline components, Ken proved that it can be done with off-the-shelf parts. To gain high-horsepower at the sacrifice of torque, even larger heads, race compression, and radical roller cams would get this same displacement right up to the 800hp. But torque rules the street.Grunt, Oomph, Twist. That's real power. Power is what Mopars are known for. At the root of that power, the key to wheel-lifting launches and asphalt-rippling burnouts is torque. Torque is also what defined 1960s muscle cars. While today’s four-valve, DOHC, fuel-injected vehicles offer performance, you don’t hear much about torque--nor do you feel it. Today’s high-revving, light-switch-for-power engines are super-efficient, clean burning, and high-revving. But they lack pin-you-in-your-seat power that forces you hang on when the pedal hits the floor. Heck, in some cases, a torque monster doesn’t require even moderate accelerator pedal travel. Perhaps that is why when Holley chose to build ten project cars--one from each decade of the company’s existence--there was no question that the automotive selection for the decade beginning in 1960 would be a big-block Mopar. Holley Performance Products and its brands including Lunati, Hooker, Earls, Holley Superchargers, Weiand, and Nitrous Oxide Systems all have an affinity with large cubic inch, V8 muscle. The choice to go with a Mopar for a decade as important as the 1960s is significant commentary regarding whose muscle cars made the most power consistently.  Ken and the crew at Indy Cylinder...  Ken and the crew at Indy Cylinder Head started with Mopar Performance Parts' cast iron street RB block (P4529851). Termed a water block, it maintains water flow between cylinders for the demands of street use as opposed to the siamesed bore offerings. Siamesed-bore RB blocks can be bored to 4.500-inches. As received from MPP, the "water block" maintains the stock 4.25-inch bore diameter; however, Indy Cylinder Head opens it up to a 4.375-inch bore--which is "the largest bore diameter this cylinder block can accommodate," according to Ken Lazzeri. All of the MP RB blocks have the stock 10.72-inch deck height.  Indy's capability as a full-service...  Indy's capability as a full-service engine builder extends from their own block and cylinder head designs and castings to their seven large CNC machining centers for customer-specific machine work, as is shown here. The same processes used on their own line of Indy Cylinder Head products are also applied to Mopar Performance blocks like the one used in this 542ci application.  Specific machine work for...  Specific machine work for the 542ci combination includes clearancing the lower skirt of the bore for rod clearance on each cylinder. The CNC's precision work guarantees exactly the same results every time.  Because Ken chose to accommodate...  Because Ken chose to accommodate the use of a Lunati crank in this application, additional clearancing near the original location of the internal oil pickup required that the pick-up be fed from the pan rather than the stock block location. The CNC work accomplished here shows the cross section of the block's original internal oil pump pick-up location and orifice leading to the stock external pump.  The popular P4529851 block...  The popular P4529851 block features both the Hemi mounting pads and the Wedge motor mount ears.  When weight is a factor, Indy...  When weight is a factor, Indy Cylinder Head also removes the Hemi motor mount pads to flush on their in-house CNC which results in up to a 45-pound weight reduction per block.  Part of the effort in building...  Part of the effort in building the 542ci stroker RB engine for Holley Performance Products' Project Roadrunner was to further determine the feasibility of using a forged Lunati crank. The Lunati crank is formed from a "generic" forging--a die that would fit big-block Chevrolets, but could be used for any big block with the same bore spacing. The assumption was that this generic crank could also be used in other applications. Holley plans on a late-2000 release of an RB crankshaft for big-block Mopars.  Obstacles to making this work...  Obstacles to making this work are apparent first from the view of the flywheel flange. For Chrysler automatic applications, we are uncertain what the results would be with the thicker flange when mounted to the torque converter. Clearances would require measuring. Four-speed applications like that of the Holley Roadrunner will have no problem with this situation.  Ken Lazzeri is quick to point...  Ken Lazzeri is quick to point out that the Lunati crank is made of excellent material, however, the forging die is that of a big-block Chevy design. As a result, the counterweights are too short. On a Chrysler-specific forging, the measurement from the bearing surface to outside edge of the counterweight is 2.400 inches as indicated by the dotted line in the photo. On the Lunati crank--shown here--the measurement is 2.200 inches. That .200-inches short is critical--especially as it relates to your wallet. It takes as much as $750 in balancing expense to add enough Mallory metal to the counterweights to balance the Lunati crank assembly. When using a standard Chrysler forging, that balancing expense would run approximately $250.  The combination of a stock...  The combination of a stock length, 6.760-inch Eagle rod; 600-gram Lunati custom relief piston; and 160-gram full-floating .990-inch diameter wrist pin makes up the remainder of the rotating assembly. The rods are retained by ARP bolts. For a street engine, this is much lighter than usual and probably assisted Indy in breaking the 500hp barrier and offered increased rev-ability.  The Lunati forged, 40cc reverse-dish...  The Lunati forged, 40cc reverse-dish piston offers the 542ci Indy engine ample combustion chamber size, despite a zero piston deck height and the 78cc chamber volumes of the Indy 440SR heads. This is important. In order to eliminate any chance of detonation with the moderate 9.5:1 compression ratio, the temperature throughout the chamber must be consistent. As a result, combustion occurs predictably across the piston surface. As bore diameters increase, this "squish effect" is harder to control, and when not considered, detonation is a likely result. The series of narrow grooves just below the piston surface are anti-detonation grooves. They also help reduce the chance of detonation as the grooves disperse raw fuel along the cylinder wall through piston travel rather than allowing it to reservoir along the ring and piston top surface. While on the topic of rings, the set is made up of 1/16, 1/16, and a 3/16 standard tension oil ring. The Holley Roadrunner will primarily be a street machine, yet we intend to do a little racing. We made it clear to Ken that we wanted both power and seal without the oil contamination that looser, high-horsepower race engines are known for.  The cylinder head for the...  The cylinder head for the 542ci Holley Roadrunner would be Indy's 440SR head. Using 906 castings as a baseline, the 440SR is Indy's first step in terms of a performance gain with its extensive line of Mopar-specific B/RB cylinder heads. Designated a street/strip head, the 440SR is the closest thing to a stock replacement that Indy offers. It doesn't require an offset rocker arm--any 906 style rocker will work, as will any intake manifold in the aftermarket.  According to Ken, "Our goal...  According to Ken, "Our goal with this head in this application was to produce a peak intake airflow rate of 320cfm while maintaining intake port runner volume at a moderate 270ccs compared to a ported 906 head's volume of 190cc." As for flow balance, the exhaust port is 75 percent of the intake and deemed a high-velocity head, perfect for the moderate airflow goal we were interested in obtaining. "Will the 542 make the most horsepower with this head?" you ask. "No," according to Lazzeri. "This engine has far more potential--it is basically a detuned race engine specifically designed for a street machine. With a much larger port volume and greater airflow volume rates, the 542 could easily produce 800hp with a roller cam, high compression, and fully ported heads--maybe even with the 440SR head."  Ken is quick to note that...  Ken is quick to note that Mopars have always been well known for torque. "Recognize that the 320cfm intake airflow rate for a 440 may have seemed large for a torque-only engine, but remember Chevrolet offered airflow rates of 270cfm right from the factory with 396 Chevrolets." As airflow goes up proportionately with port size, so does horsepower, as long as the engine can effectively pump the air available.  Sure, a race-compression 542ci...  Sure, a race-compression 542ci engine could produce 800+ horsepower, but what we wanted was street reliability and torque. Opening the Lunati catalog to camshafts, Ken chose Lunati's hydraulic PN 33706. Technically, it has the look of an MP Purple Shaft cam with a generous 110-degree centerline. Specs are .507/.534-inch lift, intake and exhaust, respectively, with an advertised duration of 285-degrees on the intake and 295-degrees on the exhaust. Duration at .0500-inch lift is 235/245, intake and exhaust, respectively. Ken chose to install the cam 3-degrees advanced, reducing the centerline to 107-degrees. For those of you with 383s, 400s, and 440s who think this cam is a bit too aggressive, remember, our displacement is 542ci. Ken says, "With that kind of displacement, you don't even hear the cam at idle."  A Lunati 3-position cam chain...  A Lunati 3-position cam chain and sprocket set is used as a Roller thrust button to reduce friction. Here, Ken readies the thrust button for installation with a liberal coating of lithium grease for startup and break-in. No oil is squirted to this location.  The overall simplicity of...  The overall simplicity of the top side of each cylinder head adds to the durability and reliability of our 542ci combination. The 1.5:1 Indy SR roller rocker was chosen here, but remember, any aftermarket adjustable rocker system will fit, including the stock 1.5:1 rockers.  For the ultimate in street...  For the ultimate in street performance, what else would you choose besides a dual-plane intake, Indy style? This manifold (PN 440-20) offers better throttle response than a similarly-sized single plane, but with the amply-sized runners, there are few single planes that actually displace more air for Chrysler B/RB engines. The efficiency of the dual-plane design assists to make the 542 a clean burning engine, even if it is a thirsty one. The throttle response is staggering and the wide power band from 1,500 to 6,000 rpm makes this the perfect manifold for big-inch Wedge engines. If you are looking for a universal B/RB manifold, this is it! It fits 906 castings as well!  To ride aboard the giant dual...  To ride aboard the giant dual plane, a carburetor capable of 900+ cfm of airflow was necessary, but not of the racing variety. Ken Lazzeri swears by the Holley Pro Series List 4150, especially PN 80497. "The Pro Series vacuum secondary carb is super responsive," says Ken. "On a street car, you want controlled secondary response and that is what the vacuum secondary carb offers." However, if you needed large cfm air/fuel flow, you were out of luck as it came in sizes only up to 750cfm. Now, Holley has addressed that with this "made-for-strokers" 950cfm carb. The radiused venturies offering smooth airflow are what distinguish a Pro Series carburetor from other Holley list 4150s.  If you were to label anything...  If you were to label anything about this combination as exotic, you may look to the oiling system.  Charlie's Oil Pans supplied...  Charlie's Oil Pans supplied the 7-inch sump design which carries a simple static pick-up with a side exit due to the relocation to an external feed/pump. This pan will fit all Mopar body styles.  Indy's SR heads require the...  Indy's SR heads require the use of Indy's 440-10 external oil line kit for rocker arms. To assure adequate top-side oiling, the external feeds run from the gallery plugs at the rear of the engine to the cylinder heads and then to the rocker shafts. Stock Mopar heads oil between the ports to the rocker shafts. Indy chooses to move the passage to the outside in order to gain a larger port cross section. Thus, airflow increases when the passages are eliminated.  The Indy MAXX external pump...  The Indy MAXX external pump with spin-on filter was necessary as noted previously by the elimination of the pick-up location due to the increased stroke requirements to gain 542ci. This gerotor style pump exceeds the stock pump flow characteristics. The billet pump cover is CNC machined to assist in high volume oil flow--a bigger system than stock which is great insurance in stroker applications.  The pan-mounted oil line is...  The pan-mounted oil line is situated to allow use of stock motor mounts. The external feed line can be routed any way necessary for any application. Every car fitment is different and this pump configuration allows for that.  As part of the camshaft degreeing...  As part of the camshaft degreeing effort, Ken measures plunger travel at the cam lobe at .050-inch lift using a lifter bore gauge.  Another critical measurement...  Another critical measurement is the deck height spec. The zero deck height of the 542 engine, when combined with the 40cc reverse dome piston, CNC-ported 78cc chamber, and .042-inch thick gasket calculated to a compression ratio of 9.5:1. In stock displacements (383/400/426/440), this could be as low as a 6:1 ratio, but keep in mind that this 542 has an additional 100 cubic inches.  Once the cam was degreed to...  Once the cam was degreed to TDC, final assembly included the use of a conversion keyway in order to fit the Mopar Performance Parts dampener to the Lunati crank. Here, a Mopar Performance timing tape is being applied to the dampener.  Indy's dual-plane intake has...  Indy's dual-plane intake has a raised intake and does not have an integral airgap plate, necessitating the use of Indy's Valley Plate (PN 440-6).  In order to gain seal between...  In order to gain seal between the valley cover and the bottom edge of the 440SR heads, a bead of RTV is added along each side of the valley cover prior to torquing the heads.  Head bolts are from Manley,...  Head bolts are from Manley, available as Indy PN 440-16.  Prior to buttoning up the...  Prior to buttoning up the final assembly and dynoing the combination, Ken adjusts the rockers. His procedure is to lock the adjuster to zero lash then add an additional 3/4 of a turn. Ken says, "Do this and you'll never have to lift the rocker covers again." Dyno Results The goal was torque and Ken Lazzeri certainly made good on his promise. Ken says, "Indy Cylinder Head has built many of these engines at 500ci, and we wanted to know what would happen if we did a 542. The result was that the torque went way up. With the 500ci combination, 600-610 lb-ft is about the max. The additional 42 cubic inches proves that there's no replacement for displacement as Ken went up to 700 lb-ft with this combination. All results gained from Indy Cylinder Head 300 rpm/second Acceleration Test conducted on SuperFlow 901 dynomometer.
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