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View Full Version : One of a kind 502 rebuild project



VegasHallett
08-21-2007, 12:01 PM
I decided to rebuild my 1999 502 mpi with a side mounted 2.3L whipple to add some extra power. After many discussions with the engine builder (LJ Engines) we decided to do something that I believe has not been done before. He rebuilt the motor to a 540 with only using the engine block. However, to make more power he had to competely change the intake manifold, injectors and throttle body.
We decided to install a Holly intake and still use the the top section of the mercruiser air plenum, so the whipple would still be side mounted. We also added a 2000 cfm throttle body and made some special adapters to accomodate the larger throttle body and brackets to support the weight from the supercharger. The engine goes on the dyno tomorrow and hopefully we make a substantial gain in the HP department. Many hours of machine work and time went into the intake modification and is very unique.
I could of made it easy by buying a updated whipple intercooler and top mount the supercharger. However, I did not want to modify my rear hatch to accomodate the height of the supercharger or pay thousands for a different intercooler.
The following is a list of parts that were included and some photos.
GM 502 BLOCK/4.500 BORE
4340 STEEL CRANK 4.250 STROKE
MANLEY 6.385H-BEAM RODS/ARP2000 BOLT UPGRADE
MAHLE PISTONS
MAHLE/TOTAL SEAL PISTON RINGS
MICH. 77H-SERIES BEARINGS
L&J CUSTOM HYD. ROLLER CAM
MELLING HV OIL PUMP
GM 8QT. MARINE OIL PAN W/WINDAGE TRAY
HD OIL PUMP SHAFT
1 PIECE OIL PAN GASKET
CLOYES TIMING SET/HEX/ADJUST
ATI 7.75 DAMPNER
COMETIC HEAD GASKETS
ARP HEAD STUD KIT
INTAKE GASKET
PUSH RODS/MANLEY PRO
INTAKE VALVES (STAINLESS/MANLEY)
EXHAUST VALVES (INCONELL/MANLEY)
PC SEALS
ROLLER VALVE SPRINGS/ISKY TOOL ROOM
DAMPNER SEAL
ROCKER STUDS/ARP
PUSH ROD GUIDE PLATES/COMP CAM
STEEL 10º RETAINERS/MANLEY
10º VALVE LOCKS/MANLEY
COMP CAM ROLER ROCKERS
INTAKE PLUNNUM/L&J MODIFIED
RHS/L&J MODIFIED IRON CYLINDER HEADS
OIL COOLER
CRANE HYDRAULIC ROLLER LIFTERS
2.3L WHIPPLE SIDE MOUNT SUPERCHARGER/INTERCOOLER KIT
2000 CFM.BILLET THROTTLE BODY
L&J MODIFIED WHIPPLE THROTTLE BODY ADAPTER
9.2 COMPRESSION
Has anyone heard of this intake modification before?? Anyone want to guess on the HP and torque?

Jbb
08-21-2007, 12:05 PM
https://www.***boat.com/forums/attachment.php?attachmentid=37607&d=1187726400
https://www.***boat.com/forums/attachment.php?attachmentid=37608&d=1187726413
https://www.***boat.com/forums/attachment.php?attachmentid=37609&d=1187726425
https://www.***boat.com/forums/attachment.php?attachmentid=37610&d=1187727119
https://www.***boat.com/forums/attachment.php?attachmentid=37611&d=1187727147

VegasHallett
08-21-2007, 12:13 PM
More photos

Krumbsnatcher
08-21-2007, 12:50 PM
I would like to know how your dyno went, i just built a 540 using the ASM kit, and it basically uses the stock GM parts. With my size cam being mild but not stock we had (Westec Performance) a bitch of time finally getting the motor to idle.
Mine pulled 605HP 600HP before falling off torque.

VegasHallett
08-21-2007, 01:05 PM
LJ Engines has a special cam for this project and he wants to keep the specification private. I don't blame him at all. The motor should dyno around 850hp give or take 25 HP. :idea:
I'll post the HP/Torque amounts and the sheet upon receiving the info.

frdvschvy
08-21-2007, 01:31 PM
Very unique combo. Looking good. Will be interesting to see what kind of numbers are generated.

Beer-30
08-21-2007, 02:07 PM
So when is the IMCO, MAX, or TEAGUE drive going on? :D

VegasHallett
08-21-2007, 02:13 PM
I have a new Bravo XR. However, I'm adding a minus 2 inch IMCO lower unit. I'm pretty easy on drives but I know this isn't going to last for long.
I used a stock Bravo 1 with the blown 502 for a couple of years with no problem but decided to upgrade to an XR for insurance reasons. Now with the new motor, I'll have to rethink the outdrive issue. I just want to last until this winter.

HALLETT BOY
08-21-2007, 02:18 PM
Nice looking engine Jeff, let me know when it's all together and we'll meet and see how it runs...

VegasHallett
08-21-2007, 02:29 PM
We are going on the test runs hopefully Friday with the engine builder, programmer and rigger. We are going to try different props and see what we can get too. I'll keep you updated...

C-2
08-21-2007, 02:52 PM
However, I did not want to modify my rear hatch to accomodate the height of the supercharger or pay thousands for a different intercooler.?
Come on now, we're not the wifey...we know why you did it, lol:D

VegasHallett
08-22-2007, 09:40 AM
Here is a photo of the piston we are using compared to a JE piston. The engine is up and running and should have some dyno results soon.:D
Any HP predictions????

VegasHallett
08-22-2007, 09:17 PM
Dyno sheet is coming soon. However here are some dyno numbers.
Horsepower = 825/850HP @ 5600RPM (SOME BLOWER BELT SLIPPAGE)
Torque = 864FT/LBS TORQUE @ 3900RPM (HOLDS 800+ FT LBS FROM 2500RPM TO 5300RPM).
INLET AIR TEMPERATURE = 105º-115ºF (115ºF @ STEADY STATE RUNNING/MAX BOOST)
KNOCK SENSOR = NO KNOCK SENSOR ACTIVITY DURING POWER RUNS
EXHAUST GAS TEMPERATURE RANGE = 1265º-1380ºF @ MAX BOOST
BOOST RANGE = 6.4 - 7.3PSI
TOTAL IGNITION TIMING = 28 to 32 degrees
The engine also made 730hp/766 lbs torque with only 4.5-5.4 PSI of boost.
LJ engines will be coming out with a kit and project price very soon. If anyone has any questions about this project or any other engine combo, email him at ljengines@msn.com
This guy is awesome and has a lot of knowledge. He works with your budget and does not do anything half a$$. More info to follow.....

Daytona100
08-22-2007, 10:31 PM
Sweet setup. Nice job. Mike:D

Sleeper CP
08-22-2007, 10:46 PM
Those are some nice numbers. Love those supercharged trq #'s
Sleeper CP

scarabrick2
08-23-2007, 04:29 AM
WOW.......
Sweet looking setup ....
What was the DYNO room temp? Was it a normal dyno room with NO a/c?
So the air coming into the motor was like ????? 90's ?
That great numbers !!!!!! Looks like a lot of work for the engine builder....
Keep us updated

VegasHallett
08-23-2007, 07:47 AM
The room was not air conditioned and was pretty hot. The air temp inside the room was around 95 degrees during testing.

VegasHallett
08-23-2007, 01:10 PM
Here is a dyno sheet from the testing.:D
Does anyone know how to put this sheet in the text box?

scarabrick2
08-24-2007, 09:05 AM
Nice :d

VegasHallett
08-27-2007, 05:04 PM
Going out for the lake test this Thursday at Lake Elsinore. I'll post some results when I get back. Hopefully the weather and drive will hold up for some speed runs.:D

scarabrick2
08-31-2007, 07:36 AM
Water testing this morning !!!!!!!!
Hopefully everything goes well.
I know he said "GT marine" helped out a lot on the install. Gary has a great knowledge of boats and runs a first class buisness. All his guys were very helpfull and knowledgeable.
Gordon from ,"Paul Pfaff Engines" is doing the custom tune... I'm sure he'll dial it in as always. He's one of the best in the buisness.
I believe he's going to set the blower speed up for a nice easy 4 lb boost. That keeps the air intake temp down. Rember its a little side mounted 2.3 WHIPPLE. They have small intercoolers. Plus Jeff has A smaller pulley for those, GO fast days :D :D :D

scarabrick2
08-31-2007, 08:05 AM
Well he's at 85 mph on the gps with some tabs down.
Motor running strong and only had it up to 5250 rpm's
He's going to run it @ mead this weekend and spin it up to 5600 or so.
so 5250 rpm's @ 85 mph.
Not to shabby :D :D

HALLETT BOY
08-31-2007, 08:30 AM
85 is moving in a 27 footer ! especially as heavy as a Hallett...

scarabrick2
08-31-2007, 04:39 PM
He Just put on a 30" Thanks 2forcefull for the loaner !!!!!!!!!!!!!!!!
Should get a few more rpm's out of it. Plus the boat was over trimmed a little and dragging more tabs than usual. should see high 80's to 90 this weekend.

VegasHallett
09-03-2007, 02:45 PM
Well I'm still working out some prop issues but here are some speed numbers from this weekend at Lake Mead.
88 mph @ 5250 rpm (7.5 Pounds of boost) with a stock 32p prop. The ambient temp was 106 and the water was flat.
85 mph @ 5800 rpm (8.5 Pounds of boost) with a stock 30p prop. The ambient temp was 109 and the water was flat.
Looks like I need a labbed 32p prop to pick up about 300 rpms and to get over 90 mph in the heat of the day. Motor ran great but still need to make some adjustments.

scarabrick2
09-11-2007, 03:23 PM
Anybody have a 32 labbed he can borrow for the weekend here @ Lake Mead ?????