509 build for "Thunder"

Discussion in 'Street Build Threads' started by TKerr, Oct 10, 2018.

  1. TKerr

    TKerr Supporting Member

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    This thread could probably also fall in the engine performance and computer swap thread as well. That being said, I am finally starting on building the 509 for my big black beast "Thunder". I will try to update this thread on a regular basis as build and time allows. I will attach pictures as the build progresses. Here is the low down on the engine and the goals.

    Acquired a Mercruiser 502 out of a boat with a steel forged rotating assembly. Engine has been bored .30 over making it a 509. The heads are 454 rectangular port heads. I will be staying fuel injected. Found a Mercruiser 525 EFI system and will be swapping in a 0411 computer and using either HP or EFI live to tune it (decision not made). Once engine is done I will build the 4l80e transmission to handle the horsepower.

    Rotating assembly has been balanced:
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  2. TKerr

    TKerr Supporting Member

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    Cam and pistons:
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  3. TKerr

    TKerr Supporting Member

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    Heads, roller rockers, other parts:
    20180731_151647.jpg 20180731_151644.jpg 20180731_150834.jpg 20180731_150741.jpg
     
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  4. TKerr

    TKerr Supporting Member

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    The intake and injection system to be used is a Mercruiser 525EFI. Injectors will be replaced with 80lb injectors.

    s-l400 (4).jpg s-l400 (2).jpg s-l400 (3).jpg s-l400 (1).jpg
     
  5. TKerr

    TKerr Supporting Member

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    Teardown and removal of the 454 has begun:

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  6. TKerr

    TKerr Supporting Member

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    Tear down under way.
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  7. TKerr

    TKerr Supporting Member

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    Having a valve train tray is extremely important. Even though I am not use my old components on the 509 I still plan on rebuilding this engine later, and a good valve tray is a must in my opinion.

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  8. TKerr

    TKerr Supporting Member

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    509 is assembled
    20181108_211131.jpg 20181108_211231.jpg 20181108_211254.jpg 20181108_211333.jpg 20181108_211445.jpg
     
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  9. TKerr

    TKerr Supporting Member

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  10. TKerr

    TKerr Supporting Member

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    Like any build I have exceeded my build budget already. If I would have stayed with the flat top pistons, smaller cam, and used some of my reusable parts (valve train components, balancer, etc) I could have saved quite a bit. But I think it will be well worth it. I am still extremely cheaper than buying a similar crate engine.
     
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