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440 Block Engine Buildup & Dyno Test - Six-Barrel PokerStacking The Deck Without Showing Your Hand From the December, 2003 issue of Mopar Muscle By Randy Bolig Photography by Dave Dudek
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Ever since wheels were mounted to the first orange crate, the quest for gains in automotive performance has been the topic of discussion. Remember those days-hanging out with your buddies, talkin' smack about how your go-cart can whoop their go-carts any day? Times haven't changed that much. We still hang around with our buddies talkin' smack, but now it's on a grander scale. Some guys dream of having an engine with enough billet accessories to put Boyd Coddington into early retirement. Thankfully, though, the performance-minded guys know what it takes to make a car go fast, not just look the part. We decided to follow along as the staff at Automotive Machine in Fraser, Michigan, built a resto-looking 440 powerplant that delivers a larger-than-factory number. We say resto-looking because the engine now displaces 496 ci. It's not an exotic, uild-it-with-your-fat-wallet-because-you-have-all-the-money-in-the-world engine. It's a common-sense approach that shows what paying attention to details and parts can do. After the block is cleaned-and... After the block is cleaned-and before any of the machine work is done-it is sonic checked. This process is sometimes overlooked, only to find out during the machining process that there is a problem with the block. After the engine was built, it was installed in Doug Johnson's '69 1/2 Road Runner and put to the test on AP Engineering's Mustang chassis dyno. Doug installed Promax metering blocks so he could better tune the outboard carbs at the dyno. He also removed the factory 30cc accelerator pump and put on 50cc pieces. The center carb was jetted with 62s on both sides, and the outboard carbs were jetted identical to start-85s on the driver side and 83s on the passenger side. The vacuum secondaries had the yellow springs installed (the lightest available). With the Runner pulled up on the dyno, the first thing to do was drill the exhaust pipe for an O2 sensor to monitor the air/fuel ratio. After the Six-barrel was brought up to operating temp, we made the first pull, which came in at 356 hp at 5,100 rpm and 401 lb-ft of torque at 4,200. It was a little less than expected, but A/F was showing the engine running a little lean.  After the block has passed...  After the block has passed the sonic check, the machining begins. As shown here, the block is parallel and zero-decked (A), the cylinders receive a .030-inch overbore (B), and the oil-pan rail receives the required machining to make room for the 4.15-inch crank and Eagle connecting rods (C).  After the block has passed...  After the block has passed the sonic check, the machining begins. As shown here, the block is parallel and zero-decked (A), the cylinders receive a .030-inch overbore (B), and the oil-pan rail receives the required machining to make room for the 4.15-inch crank and Eagle connecting rods (C).  After the block has passed...  After the block has passed the sonic check, the machining begins. As shown here, the block is parallel and zero-decked (A), the cylinders receive a .030-inch overbore (B), and the oil-pan rail receives the required machining to make room for the 4.15-inch crank and Eagle connecting rods (C).  Proper engine balancing is...  Proper engine balancing is a must for any high-performance engine.  After the rods are checked...  After the rods are checked for proper journal sizing, the pistons are assembled. Doug chose Diamond flat-top pistons. The combination yields an 11:1 compression ratio.  The Crane PowerMax HR-230/352-2S-12...  The Crane PowerMax HR-230/352-2S-12 hydraulic cam is installed, and ring end gaps are checked. The end gaps measure .025 inch for the top ring and .023 inch for the second ring. With the pistons installed,... With the pistons installed, the number 1 piston is brought up to TDC in order to begin the cam degreeing procedure per the cam card. For the second pull, we increased the jetting to 87 on the driver side and 85 on the passenger side on both outboard carbs. Timing was bumped from 36 degrees to 39 degrees total advance. The second pull responded with 376 hp at 5,200 rpm, and 417 lb-ft of torque at 4,200. The A/F ratio was still a tad lean, dancing in the 13.6 range. On the third pull, we upped the jetting to 88 on the driver side and 86 on the passenger side. This pull responded with an A/F ratio of 12.7:1 at peak horsepower, but the horsepower numbers didn't show a substantial increase. The final tally was 377 hp at 5,200 rpm, and 417 lb-ft of torque at 4,200. It was almost a mirror image of the previous pass. We figured there weren't any gains from jetting, so we played with the timing some more. We began by moving it back down to 36 degrees total and lost 4 hp and 5 lb-ft of torque from our peak numbers. Once we moved the timing back up to 39 degrees, we were ready to hit the track for some testing. Getting a car in the F.A.S.T. class of racing to launch requires a lot of finesse with the throttle pedal. If you're wondering why, just take your stock, Mopar-powered anything out on the street and try to take off really quickly without spinning the little repop redline tires on your ride. With the finesse required-and the fact that Doug leaves his car in Drive when he races-the Road Runner has still posted a best quarter-mile time of 12.16 at 115 mph. Give him a little more time behind the wheel and 11s are definitely within reach. Keep in mind that this engine uses a stock intake manifold with three Holley carbs, as well as stock exhaust manifolds.  One of the 906 heads is installed,...  One of the 906 heads is installed, and valve-to-piston clearance is checked. A minimum of .080 inch for the intake valve and .100 inch for the exhaust valve is recommended. The heads were prepped at Modern Cylinder Head in Clinton Township, Michigan. The intake valves are 2.14 inches, and the exhaust is 1.81 inches. The ports feature a full porting and polish job.  Once the engine is assembled,...  Once the engine is assembled, it's tested to assure there's no excessive leak-down around the valves and rings.  The oiling system is prim...  The oiling system is primed.  After receiving accessories...  After receiving accessories such as the intake and carbs, oil pan, and exhaust manifolds, the engine is installed in the car-a '69 1/2 lift-off-hood Road Runner that will race in the F.A.S.T. class. This class dictates that the car look factory stock. Of course, looks can be deceiving.  Dyno Dueling Once the engine...  Dyno Dueling Once the engine was installed, the Road Runner was taken to AP Engineering for dyno'ing. AP utilizes a Mustang chassis dyno, and its results are quite consistent. Not a large amount of tuning was required on the dyno. Carburetion was tuned with the help of Promax Carbs metering blocks and the addition of 50cc accelerator pumps. The Promax metering blocks allow the outboard carb jetting to be changed as needed. Factory-prepped outboard carbs were not supplied with changeable jets. The only other changes made were to the timing until the optimum setting was found.  The carbs may look stock,...  The carbs may look stock, but thanks to the aid of the Promax jetable metering plates, fuel and air flowing through the outboard carbs can be adjusted for maximum horsepower. | 440 Head Flow Test, Flowed | | With A 4.320 Bore At 28 Inches | | Inches Lift | Intake | Exhaust W/No Tube | | .100 | 22.4 | 94.4 | | .200 | 150.0 | 102.2 | | .300 | 207.8 | 165.4 | | .400 | 252.9 | 175.4 | | .500 | 285.2 | 196.5 | | .600 | 292.7 | 208.0 | | .700 | 301.1 | 237.8 |
Dyno Results | RPM | TQ | HP | | 3,600 | 292 | 200 | | 3,700 | 316 | 223 | | 3,800 | 375 | 272 | | 3,900 | 395 | 294 | | 4,000 | 406 | 310 | | 4,100 | 415 | 324 | | 4,200 | 417 | 333 | | 4,300 | 413 | 338 | | 4,400 | 407 | 342 | | 4,500 | 407 | 349 | | 4,600 | 405 | 355 | | 4,700 | 405 | 362 | | 4,800 | 403 | 368 | | 4,900 | 399 | 372 | | 5,000 | 393 | 375 | | 5,100 | 387 | 376 | | 5,200 | 380 | 377 | | 5,300 | 371 | 375 | | 5,400 | 364 | 374 | | 5,500 | 358 | 375 | | 5,600 | 348 | 371 | | 5,700 | 340 | 370 | | 5,800 | 329 | 363 | | 5,900 | 306 | 345 | | 6,000 | 289 | 329 |
Checked At The Rear Wheels On The Mustang Chassis Dyno
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