Finally making progress on the 242!!
 

Winter really caused some delays with getting my 242LS back together, but I'm really starting to make some good progress at this point!

Here's a recap and where we are:

1. While trying to remedy some issues around Bravo-itis (mainly installing a thru-transom water pickup because the transom inlet was blocked), we found that the transom was rotted. Further examination showed rot damage to the battery/pump/anchor shelves, rear stringers, engine stringers, rear bulkhead. Basically, the entire back-half of the boat was screwed.

2. Interviewed a number of folks for the job. Considered doing it myself, but then decided that it would never get done. A friend ended up doing the work at a third of the cost, but took over a year to get it done (not a problem).

3. Boat back home in the fall of 2014, then sat over the long winter while trying to figure out the engine program. Stock with some upgrades/bling? Or something that would really move? I was thinking that the best way to make power would be to go with a blower. That turned into a blower and a roller cam. That then turned into a blower with a roller cam and some new Dart heads!

4. Bilge painting back in April... I didn't like the gray, and white makes it very easy to spot issues. Also had my friend that did the structural work reinstall the transom assembly.

5. Engine teardown began in December, block and rotating assembly to the machine shop in January. Parts ordering began, and then the winter set in, HARD. The garage was too cold to even think about getting accurate measurements. Ran into a lot of troubles getting the right bearings, etc. Not fun. Finally, after lots of hard work, the engine was finished last week. Just need some AN fittings, and valve covers (ordered from Teague).

6. Major cleanup began this weekend. I need the boat clean in order to re-rig everything. Frankly, it was too depressing to look at. The seats were full of mildew, and there was fiberglass dust EVERYWHERE. Let me tell you, Tilex is my new best friend! After cleaning, I went at reinstalling the battery boxes, trim pump, and wiring. I'm hoping to be done with the bilge this week. Engine goes on the dyno next week. My goal is to be back on the water by my birthday (June 30th).

Engine specs:

454 mag short block, standard bore and stroke. 9.8:1
Dart 360 heads, girdles, Comp stainless rockers, Ferrea Super Alloy valves
Bob Madura 525 EFI cam (Crane 741 but with a 114 LSA)
B&M 250 Powercharger
Dual Nickerson 850s

Should make some really good power!!


Here are some pics in no particular order (excuse the paint chips on the blower; shipping was sloppy at best. I have touch-up):

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Tom that looks great it looks like you pulled the tank also or did you just put new foam in? I can't wait to hear what kind of numbers you pull from that engine.

mark

We didn't pull the tank. There wasn't any rot beyond the bulkhead, and the tank showed no signs of leaking. The foam was removed in order to reach the back-side of the bulkhead. Work was done just forward of the bulkhead back. He did some really good work on it.

I'm excited to get the engine on the dyno. It should make at least 600 HP depending on boost. I have a 2.75 pulley on it now, but we'll only use that for bragging rights. It's too much for pump fuel even with the aluminum heads. I'm shooting for 5-7 lbs with a 3.30 pulley.

Looks good! Keep us updated. Nice to see another local formula owner!

Thanks!!

Mounted trim tab pump, reran some wiring and hoses. Removed all the tape marks from the hull. Stared and drooled at/over the engine for a while. ;)

I really want to see this done. I have a 242 with a 454/420hp in it that would love a blower. Are you thinking 75mph? Hydraulic steering?

Another OSO'er (Cignificant) had a 242LS with a 250 on a 502 crate motor (no specs on the engine, but as I understand it pretty basic) that went 78 on GPS. I'm down 48 cubic inches, but more than make up for it with heads and cam/valvetrain. The heads are way overkill (got them as a gift from one of my best friends), but we're pretty sure they'll work well in giving the blower all the unrestricted air movement possible. So I'm going to say at the least 75 for sure with 80+ in range. I'm saving hydraulic steering for next season. I know the importance of it so rest assured that I'll take it easy and add it when I can.

Looks really good. It will be worth all the time once you go out and enjoy it. The white looks good too, it really updates the engine compartment.

Thanks. I thought the white really updated it, too. I used a brush-on Rustoleum oil-based gloss paint. Coverage is great, and it cures hard as a rock. Good stuff and much much cheaper (and pretty much the same thing) as Interlux BilgeKote. The gloss and hardness will make it easier to keep clean versus the old way. I'll finish painting the bottom of the bilge as a last step before the bilge hoses and engine go in.

I'm also going to upgrade the lighting in the engine room... LED strips under the gunnels and LED spot lamps in place of the utility lamps on the bench wall. Should make working in the bilge at night a lot easier. I'm think of just plain white, though I may put in multiple strips so that I can have red for night time use while operating. The hardest part is choosing what to use! So much out there..

I meant to add last night... the 420 will definitely love a blower! If you're considering it, definitely step up to a 250/256 vs the smaller 174/177 blowers. The 250 will make less heat and give you a little bit of growing room (a 420 Megablower or 6-71 would be even better). Change the head gaskets for good measure, and add Inconel exhaust valves if the engine doesn't already have them (can't recall whether or not the 420 came with them or not).

So of you guys might have seen my dyno discussion in the general tech section, but for those that didn't: 578 HP at 5500 which wasn't what I expected. Basically, I ended up shelling out about $3K to get a very tired blower set up (word to the wise... when buying used, make sure someone can backup their claims with consequences for not coming through). In the seller's defense I think he was screwed over without even knowing it. Anyway.... I'll redo the blower in the off-season.

I'm looking to have the engine back in the boat in the next week. The rigging is just about done. I finished the bilge Sunday night/Monday morning. If I can make it happen, I'll drop the engine in over the weekend! Then I just need to button up the transom assembly and get to it.

I'll get pics when I can. Here's a pic of the engine on the dyno:

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Even with the above... still should run 75-78 with a 26P Bravo 1. That's where we're starting anyway.

I hope it meets your expectations. As a reference we dynoed a 454 at 496 horse in a 242ls and it runs consistently 68 to 70. With a 365 horse mag it ran 57

What prop were you running?

23 Mirage Plus @ about 5400. Motor made max power on dyno at 5200.

Do you remember the torque? Mine is 600+ under 3K RPM.

I'd think it would spin more prop.

Torque was around 530 at 4300ish rpm where we ended up with timing at 35. Actually made more torque, 540 or so at 33 degrees but peak power fell a bit. Torque was near or above 500 at the start of the run at 3k rpms and all the way through the range.

Tom i have been following your build and that sucks that the blower is tired and your still very close to 600hp in a 242. this should be very fun to drive, we look forward to seeing this on the water.

Thanks! I know it's going to be surprising! My next direct investment will be steering (probably before fixing the blower).

On to updates...

Worked on getting the bell housing back on. What a b!tch!! I followed someone's advice and pulled the support spring from the new bellows. That was a f'ing mistake! I'll need to take it all apart. At least the new trim and tilt parts went in nicely!

I also replaced the water hose with a stainless steel tube adapter kit to fix the bravo-itis deal that led to fixing the transom in the first place. Really cool, but not easy to install, and probably near impossible with the engine in the boat (you have to pound the thing in just about). Here's a link:

http://www.amarket.com/BRAVOitis.htm

Saturday or Sunday, the engine goes back in! I've already reserved the forklift at one of our businesses!

Got forklift keys... Looks like tomorrow is the day!!!

Engine is in! The hard part is over. Everything should start to happen quickly from here on. I'll definitely be on the water this month!

I need to clean up some things before getting some pics, but I will get some to share.

Updates please !

Slow!

I have alignment issues and a broken engine mount stand. I also spent all day Saturday trying to get the Silent Thunder box back on the boat (really thinking about a tubular platform for next year). Anyway, getting there just about. I may not make my birthday deadline though. July 4th perhaps?

A couple of engine shots... proof that it did go in!

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Tom I feel your pain . My guess is if you go to nice exhaust your pipes won't line up with the holes , I'm still dealing with prop issues let me know what prop you go with when you hit the water .

I had extensions made for my 496/Gil/Merc risers. I may need to modify them some but need it running to find hot spots first.

Biggest issue at the present (besides mounts and alignment) is the fact that all of my dash switches/breakers broke. All nine of them! The breakers are good, but the covers that hold the toggles on are busted.

We're going to run. 26P Bravo 1 to start. What's up on yours?

Cant wait to see how this works out.

Some updates....

The Formula fell a little to the back-burner over the last month or so. A new girlfriend and lots of summer trips and such will do that!

Here's what's done:

- New circuit breakers for the panels. I went with a set of Blue Sea breakers. They weren't a direct fit, and I had to make them work. Clean install. And they work much nicer than the old ETAs.

- Replaced a the engine mount but still couldn't align. Found that my coupler had just enough wear to make it impossible for the tool to go in. Since the bell housing was off we decided to just use the drive for alignment. Went in smooth as silk on the first try. Done.

- Redid the bellows and all. Mounted the drive. The backend of the boat is done.

Stuff to do....

- Finish some wiring.
- Install the exhaust.
- Bleed hydraulics.

Getting close!!!

Do you still have the old ETA breakers and if so I would like to take them off your hands. Also did you change the ETA switches on the dash because those I will take too. Thanks again and congrats on your boat. I did a major retrofit like you and everytime someone pays me a compliment the smile is worth all the hard work.

I trashed everything... they were all wasted. Corrosion had eaten a lot of the metal, and the black covers would fall apart when simply handling them.

Which boat are you working on? Another 242 or?

Mine is a 1988 242LS. Final pieces I am looking for are the plastic windshild moldings to cover the screws and a set of the black plastic storage bins which hang in the engine compartment (not sure if you have ever seen them). Great for bumpers and lines.

Yep, mine was all intact, including the storage bins (love'em!).

Got any pics to share?

Any updates ?

Not really.

My exhaust and alternator are not cooperating. I bought an IMCO relocation bracket and it still doesn't work. I was looking for some Gil or Stainless Marine (or some CMI's), but decided to see what else I could do with the Merc/Gil 496 parts I have. I ordered some offset connectors to make the risers work with my Bravo tips.

I'm actually very close to being done, but have some other pressing things going on.

On another note, my engine was down on power because of a blower that I bought from here that wasn't what it was represented as being, but I found in the dump sheet (and video) that the belt was slipping badly. A new belt should put me well into the 600-625 range, even with the crap blower (pisses me off... makes it hard to trust people).

Well, it's been almost four years, and I'm proud to say that the old bird saw some water on Saturday.

First, we fired up the old girl. I haven't had the engine running since the dyno back inJune. Lots of wrenches were flying... I was like a mad scientist trying to get everything together to make it happen. Splashed some fuel down the carburetors and she fired right up! No leaks and water flowing out the exhaust. All good! She sounds nasty!

Off to the ramp!

My buddy backed her into water and I stood by nervously. "Is the transom sealed?" "Did I mess anything up?" A quick check showed me that the bilge was dry, and she was ready.

Well, we didn't get all dressed up for nothing!! Five minutes later, we were leaving the dock under power!

Our first issue, the drive decided to ignore the shift cable and remain in forward... coming back into the dock was going to be fun! Outside of that issue... I've got a rocker arm that's out of adjustment and a little fine tuning to do. I have a lot of blower surge which will make docking and no wake zones tricky.

Some observations.... 1) The boat is completely different than the last time I had her out. Gone is the rickety loose unstable feeling pre transom and stringer replacement. I guess the hull was in a lot of trouble! She's a completely different boat now. 2) She's smooth! She feels like a new boat, and she's fun to pilot!3) She's powerful. I mean really powerful! I didn't have to do much of anything to get her on plane. Just a little bit of throttle and she was up! Effortless. I didn't push the engine, but she is really responsive. A blip of the throttle and she's coming out from under your feet. Cruise at 32-3300 RPM is 45 MPH (GPS) without messing with the trim. With some seat time I can probably get to 50 MPH at cruise (that was one of my goals with the build).

Coming into the dock was interesting (dead sticking it because I couldn't get her out of forward). Thank goodness I had some help with me! We made it look like we'd done this many times before.

Got her home and flushed everything, then gave her a well deserved bath. I have a lot of polishing to do, but she looks a ton better.

I'll see if I can post a couple of pics.

Good to hear !! What are you running for ignition ,fuel pump, and prop ?

Cool update. You brought back a vivid memory when you mentioned worrying about the transom being sealed. I must have spent 10 minutes nosing around in my 311 when I splashed it before the butterflies went away enough to start it. It was kind of surreal pulling away from the dock for the first time after 3 years of it being out of the water.

As for your rocker adjustment, what lifters are you running, Morels? My motor clattered like hell for the first couple of hours, and then it quieted down. It would always make some valvetrain noise when cold but would go away after 10 minutes of running. If that is what you are experiencing I would leave it alone until you put a bit more running time on it.

Ignition is the stock Merc TBIV with V6 module, fuel pump is a Teague/Baker Engineering 130 gph pump (feeding twin Nickerson 850's), and the prop is a 4-blade Bravo One.

I was super nervous! I did end up with some sea water in the bilge (gallon or so... salty) but it's probably coming from a hose connection. I noticed nothing coming from around the transom assembly.

Lifters, I did not go with Morel lifters. I'm using a set of Comp 854S lifters. We noticed this tap at high idle on the dyno, but after warming her up it disappeared. I'll pull the valve cover off and take a look next weekend.

I also have drive issues... my Bravo is a little noisy. I believe it's the shift fork bouncing around, but I need to look.

Yesterday was great!!

Is your fuel pump on the sea pump ?i been having problems with bad fuel motor not making the power it should hits a wall and been looking for ideas

Mine is MK IV so it's mounted on the block.

You have a 525SC, right? Where does it hit the wall?