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Ok motor heads lets put our heads together on some questions that i have.I have a gen IV 454. I think it is stock but ran great until saturday when i lost all oil pressure:)st Anyway i want to build a 540 bbc out of my old 454.I need some input on this. What can i expect from this build? HP??? Give me the good news along with the bad.Your help with this will lead me in the right direction .By the way this 540 will be going in a 20' jet boat. THANKS MOTOR HEADS:)hand:)hand
 

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Ok motor heads lets put our heads together on some questions that i have.I have a gen IV 454. I think it is stock but ran great until saturday when i lost all oil pressure:)st Anyway i want to build a 540 bbc out of my old 454.I need some input on this. What can i expect from this build? HP??? Give me the good news along with the bad.Your help with this will lead me in the right direction .By the way this 540 will be going in a 20' jet boat. THANKS MOTOR HEADS:)hand:)hand
i should prob keep my mouth shut! cause everytime i open it, i get in trouble :)...anyways...i do not believe that u can make a 540 out of a 454...i dont think u can bore it that far "safely", nor put the correct crank in it cause of the throws on the crank!...my suggestion would be...make it a 461 or a 468 or a 496...i personally would make it a 468!...a very good & "reliable" motor that makes good HP & will work with the parts u have...put an Edelbrock RPM Air Gap manif & 750/800cfm DP carb & up-grade the ignition on it & i think u will be "pleasently" surprized! :)...just my .02 cents for whatever its worth!

FastRat
 

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Fast is right:) you can't bore a 454 out to the 4.5" bore required to make 540 cid. But you can safely go .060 over the stock 4.25" and make a 468 with the stock crank or pick up an aftermarket 4.25" stroke crank and make a 496. with the same 4.31" bore. Hope this helps.
 

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Unless you have a Bowtie or aftermarket block, you are limited in bore size as previously stated. Most stock blocks are limited to a .060" over bore, far short of the .250" you would need to build a 540. If you decide to go large I would suggest 565 cubic inches. That's a 4.6" bore and a 4.25" stroke, basically a bored 540, but the major benefit of the larger bore other than the additional cubic inches is that it moves the cylinder walls farther away from the valves, unshrouding them and improving the engines breathing greatly. You will gain more power from the improved breathing, than the additional cubic inches.

I just had a pump gas 565 built by Sunset Racecraft in Lubbock TX that made 807 hp @ 6000, and has 770 tq @ 5100. From 3500 to 6200 the torque curve is above 680, and peaks at 770. While this engine was built with quality components, it's nothing trick. just a well concieved combination that provides good power and reliability. :D
 

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Rainy day

I don't want to rain on your parade, but you're wasting your money if you go nuts on an engine for a jet boat. Rebuild what you had. Maybe punch it out to 460 and keep it simple. Remember boats are suppose to be fun, don't create something that ruins your lake/river days, not to mention your bank account. When you start looking for huge numbers the cost goes almost straight up, and the rewards don't.........K. I. S. S. is the best advice, and fun is the goal. A jet will never be king of the water, so just have some fun.........If you go after all the power you can find, just remember you're only half done. Now you can start saving for all the pump work you're going to need to use the power monster you have created......There are NO CORNERS to cut, no "cheap" parts to use, and unless you really know what you're doing, at least 2, if not 3, dismal failures in your future. :)hand.............Ray
 

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Discussion Starter #6
Thanks guys all the advice that you all give me is very helpful. I do'nt no what to build but with all the help i will find something that will work for my boat.$$$$ do matter in this motor and reliability does matter.What do you think i can build for 3000.00 with some of my old parts like tunnel ram, carbs, heads,cam.Thanks chris
 

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Thanks guys all the advice that you all give me is very helpful. I do'nt no what to build but with all the help i will find something that will work for my boat.$$$$ do matter in this motor and reliability does matter.What do you think i can build for 3000.00 with some of my old parts like tunnel ram, carbs, heads,cam.Thanks chris
You "NEED" to re-read what Moneypit posted above...save ur hard earned $$$ & re-build urs to a 460/468...u can use all ur old parts (new pistons) & have a reliable motor! :)...maybe spend a few $$$ on ur pump...a ride plate...a place diverter...bottom line is K.I.S.S. & "GO" have fun!!!! :)...ur peace of mind & ur wallet will love u for it! :)

FastRat
 

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You "NEED" to re-read what Moneypit posted above...save ur hard earned $$$ & re-build urs to a 460/468...u can use all ur old parts (new pistons) & have a reliable motor! :)...maybe spend a few $$$ on ur pump...a ride plate...a place diverter...bottom line is K.I.S.S. & "GO" have fun!!!! :)...ur peace of mind & ur wallet will love u for it! :)

FastRat
I agree, warm up your 454 to a 468, roller rockers, tunnel ram, about a 6000 rpm cam, if you have any bread left over, buy a set of merlin heads................. Then go to work on the bottom of your boat and your pump and make the whole package work................ I don't know a lot about jet boats but I have seen people just pour the horsepower to those things and not even get by the milkman...................... I've also seen guys run them 117 mph at the drags with just a tunnel ram 468............just my .02
 

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Discussion Starter #9
You "NEED" to re-read what Moneypit posted above...save ur hard earned $$$ & re-build urs to a 460/468...u can use all ur old parts (new pistons) & have a reliable motor! :)...maybe spend a few $$$ on ur pump...a ride plate...a place diverter...bottom line is K.I.S.S. & "GO" have fun!!!! :)...ur peace of mind & ur wallet will love u for it! :)

FastRat
Thanks guys my girlfriend and my wallet thanks you.I'm going to keep it simple.We all no that all the fast boats have props on them.:)hand:)hand I think with a 30 or 60 over bore a good I beam rod and some of my old parts things will be just fine.That will leave more $$ for gas and beer.:)sphss
 

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If you stumble on a used 502 block..that's 540 material. Good luck.
It's also good 502 or .030 over 509 material while keeping your old crank and rods. The 502 and 454 use the same crank and rods. Save your money and rebuild what u got.
 

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It's also good 502 or .030 over 509 material while keeping your old crank and rods. The 502 and 454 use the same crank and rods. Save your money and rebuild what u got.

Depends on the year of the 454, while they have the same stroke the rear main seals on a MK IV are two piece, while the 502 crank has a one piece seal. Adapter are available to convert, but you should be aware it is not a drop in.
 

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Thanks guys my girlfriend and my wallet thanks you.I'm going to keep it simple.We all no that all the fast boats have props on them.:)hand:)hand I think with a 30 or 60 over bore a good I beam rod and some of my old parts things will be just fine.That will leave more $$ for gas and beer.:)sphss
What heads do you have? What intake and carb(s)?
 

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With only $3000 to work with, Just rebuild what you have. Go .030 over in case you have to bore it again in the future...
 

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With only $3000 to work with, Just rebuild what you have. Go .030 over in case you have to bore it again in the future...
that "is" a good suggestion! :)...also...after u tear it down...have the rods cked & re-sized & if they are pressed pin type, have them bored out to accept floating pins (u "dont" need I-beam rods, save ur $$$)...a good 3 angle valve job would help also

FastRat
 

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Discussion Starter #18
that "is" a good suggestion! :)...also...after u tear it down...have the rods cked & re-sized & if they are pressed pin type, have them bored out to accept floating pins (u "dont" need I-beam rods, save ur $$$)...a good 3 angle valve job would help also

FastRat
Thanks for the info. How much do you think it would $$$ to have the rods bored out to accept floating pins?
 

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I have stock 049 heads with tunnel ram and two 650 holleys
those are good heads, not great, but will work just fine with what u have! :)...a 3 angle valve job & port match the intake ports on the heads to the manif for better flow & get a roller cam & kit to tie everything together (as mentioned before)...remember, ur "not" building a race boat, rather a good running, reliable pleasure boat that u can go have fun with! :)

FastRat

p.s. cstraub on the boards can help u with a cam selection...he has "helped" many! :)
 

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Thanks for the info. How much do you think it would $$$ to have the rods bored out to accept floating pins?
if u have an "in" with a machine shop, prob nothing, otherwise, prob shop rate + labor...i would wait 'til i got the pistons & pins set to have it done, so it doesnt get screwed up!

FastRat

p.s. where do u live?
 
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