super charging a 502 efi.... where to start
11-25-2013 | 08:01 PM
#21
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Joined: Jan 2003
Posts: 957
Likes: 3
From: Brookfield, Wi.
The boat is a 1995, I painted the boat and put all new interior in it this spring. The boat runs mid 60's now with a 24p Hydromotive quad 4 prop right now. It starts to chime between 55-58 mph then smooths right back out at 60. besides that and the vapor lock issue I love it.
11-25-2013 | 08:02 PM
#22
Platinum Member
Joined: Jan 2003
Posts: 957
Likes: 3
From: Brookfield, Wi.
The boat is a 1995, I painted the boat and put all new interior in it this spring. The boat runs mid 60's now with a 24p Hydromotive quad 4 prop right now. It starts to chime between 55-58 mph then smooths right back out at 60. besides that and the vapor lock issue I love it.
11-26-2013 | 06:03 AM
#23
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Joined: Oct 2002
Posts: 2,057
Likes: 95
From: Bowling Green, Kentucky
I installed the Procharger system on the same engine except return fuel to tank and better flow fuel lines and filter. I took time tuning the fuel pressure reading the spark plugs. I ran it for several years before I sold it with no issues. It really woke the boat up and was fun. The engine had 300 some hours prior to installation. I knew this was not the "right" way to do it but it worked for me. Over the years it seems that larger boats that will see boost conditions regularly fail quicker. Generally people with lighter boats have success longer.
11-26-2013 | 12:32 PM
#24
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Joined: Nov 2005
Posts: 4,554
Likes: 3
From: Fredericksburg, Va
the cool fuel was a merc bandaid for the vapor lock issue...worked some of the time..many still had the issue...lines done correctly with a return cure the issue...
11-26-2013 | 11:13 PM
#25
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Joined: Jan 2004
Posts: 4,480
Likes: 43
From: Tennessee
IMO, there are several things that should be done if you want it to live a long life and run to its potential.
First, you should change the head gaskets to Cometics. If you are going to run over about 3 psi, then the exhaust valves should be changed to something like Manley's Inconel valves. You will also need to upgrade the fuel system. Take the Procharger regulator and throw it in the garbage. Use a standard 1:1 boost referenced regulator, like an Aeromotive. I would replace not only the fuel filter head to a larger one, but also the fuel lines and the pickup in the tank if it isn't large enough.(most are not large enough in production type boats) The fuel return should go back to the fuel tank. If the engine has over 200-250 hours, you should freshen up the heads. You will need to turn it a little harder than the stock 5050 rpm to take full advantage of the power. At 5 psi of boost, it will pull to about 5300 rpm.
Depending on the year of the 502 mags, there were 3 different versions of the fuel rails. The pre 99 versions have a few issues. The supply hole to the #7 injector needs to be opened up in a mill. Also, the rail should be fed fuel from both ends so that one end isn't run dry. There are quite a few other mods that needs to be done to the rail in order to make it really work correctly. The 99 and up rail needs less mods. It still should be fed from both ends, but it is already threaded for 1/4" NPT, so it's much easier to do.
With 5 psi boost, you should be in the 625 hp area. The stock injectors are good to about 650 hp without killing them by running them to hard. You can make more than 650, but it takes its toll on the injectors. If you have a pre 99 fuel rail, then you will have the Keihin injectors. There are no drop in replacements that are larger than the stockers. You can install larger injectors but it requires drilling out both the intake and the rails. If you have a 99 and up, they use the shorty injectors, so they can be replaced with larger ones if you want to make more power.
The other thing that must be addressed in the ecm. Obviously, it will need to be retuned. The best bet is to put it on the dyno and tune it.
We have done a TON of these. I actually have a few in the shop now that we are doing. If you have any questions or need any help, don't hesitate to give me a call anytime.
Eddie
615-216-7449 shop
504-416-3607 cell
First, you should change the head gaskets to Cometics. If you are going to run over about 3 psi, then the exhaust valves should be changed to something like Manley's Inconel valves. You will also need to upgrade the fuel system. Take the Procharger regulator and throw it in the garbage. Use a standard 1:1 boost referenced regulator, like an Aeromotive. I would replace not only the fuel filter head to a larger one, but also the fuel lines and the pickup in the tank if it isn't large enough.(most are not large enough in production type boats) The fuel return should go back to the fuel tank. If the engine has over 200-250 hours, you should freshen up the heads. You will need to turn it a little harder than the stock 5050 rpm to take full advantage of the power. At 5 psi of boost, it will pull to about 5300 rpm.
Depending on the year of the 502 mags, there were 3 different versions of the fuel rails. The pre 99 versions have a few issues. The supply hole to the #7 injector needs to be opened up in a mill. Also, the rail should be fed fuel from both ends so that one end isn't run dry. There are quite a few other mods that needs to be done to the rail in order to make it really work correctly. The 99 and up rail needs less mods. It still should be fed from both ends, but it is already threaded for 1/4" NPT, so it's much easier to do.
With 5 psi boost, you should be in the 625 hp area. The stock injectors are good to about 650 hp without killing them by running them to hard. You can make more than 650, but it takes its toll on the injectors. If you have a pre 99 fuel rail, then you will have the Keihin injectors. There are no drop in replacements that are larger than the stockers. You can install larger injectors but it requires drilling out both the intake and the rails. If you have a 99 and up, they use the shorty injectors, so they can be replaced with larger ones if you want to make more power.
The other thing that must be addressed in the ecm. Obviously, it will need to be retuned. The best bet is to put it on the dyno and tune it.
We have done a TON of these. I actually have a few in the shop now that we are doing. If you have any questions or need any help, don't hesitate to give me a call anytime.
Eddie
615-216-7449 shop
504-416-3607 cell
11-27-2013 | 10:18 AM
#26
Registered
Joined: Jul 2007
Posts: 3,648
Likes: 32
From: Oneida Lake NY
IMO, there are several things that should be done if you want it to live a long life and run to its potential.
First, you should change the head gaskets to Cometics. If you are going to run over about 3 psi, then the exhaust valves should be changed to something like Manley's Inconel valves. You will also need to upgrade the fuel system. Take the Procharger regulator and throw it in the garbage. Use a standard 1:1 boost referenced regulator, like an Aeromotive. I would replace not only the fuel filter head to a larger one, but also the fuel lines and the pickup in the tank if it isn't large enough.(most are not large enough in production type boats) The fuel return should go back to the fuel tank. If the engine has over 200-250 hours, you should freshen up the heads. You will need to turn it a little harder than the stock 5050 rpm to take full advantage of the power. At 5 psi of boost, it will pull to about 5300 rpm.
Depending on the year of the 502 mags, there were 3 different versions of the fuel rails. The pre 99 versions have a few issues. The supply hole to the #7 injector needs to be opened up in a mill. Also, the rail should be fed fuel from both ends so that one end isn't run dry. There are quite a few other mods that needs to be done to the rail in order to make it really work correctly. The 99 and up rail needs less mods. It still should be fed from both ends, but it is already threaded for 1/4" NPT, so it's much easier to do.
With 5 psi boost, you should be in the 625 hp area. The stock injectors are good to about 650 hp without killing them by running them to hard. You can make more than 650, but it takes its toll on the injectors. If you have a pre 99 fuel rail, then you will have the Keihin injectors. There are no drop in replacements that are larger than the stockers. You can install larger injectors but it requires drilling out both the intake and the rails. If you have a 99 and up, they use the shorty injectors, so they can be replaced with larger ones if you want to make more power.
The other thing that must be addressed in the ecm. Obviously, it will need to be retuned. The best bet is to put it on the dyno and tune it.
We have done a TON of these. I actually have a few in the shop now that we are doing. If you have any questions or need any help, don't hesitate to give me a call anytime.
Eddie
615-216-7449 shop
504-416-3607 cell
First, you should change the head gaskets to Cometics. If you are going to run over about 3 psi, then the exhaust valves should be changed to something like Manley's Inconel valves. You will also need to upgrade the fuel system. Take the Procharger regulator and throw it in the garbage. Use a standard 1:1 boost referenced regulator, like an Aeromotive. I would replace not only the fuel filter head to a larger one, but also the fuel lines and the pickup in the tank if it isn't large enough.(most are not large enough in production type boats) The fuel return should go back to the fuel tank. If the engine has over 200-250 hours, you should freshen up the heads. You will need to turn it a little harder than the stock 5050 rpm to take full advantage of the power. At 5 psi of boost, it will pull to about 5300 rpm.
Depending on the year of the 502 mags, there were 3 different versions of the fuel rails. The pre 99 versions have a few issues. The supply hole to the #7 injector needs to be opened up in a mill. Also, the rail should be fed fuel from both ends so that one end isn't run dry. There are quite a few other mods that needs to be done to the rail in order to make it really work correctly. The 99 and up rail needs less mods. It still should be fed from both ends, but it is already threaded for 1/4" NPT, so it's much easier to do.
With 5 psi boost, you should be in the 625 hp area. The stock injectors are good to about 650 hp without killing them by running them to hard. You can make more than 650, but it takes its toll on the injectors. If you have a pre 99 fuel rail, then you will have the Keihin injectors. There are no drop in replacements that are larger than the stockers. You can install larger injectors but it requires drilling out both the intake and the rails. If you have a 99 and up, they use the shorty injectors, so they can be replaced with larger ones if you want to make more power.
The other thing that must be addressed in the ecm. Obviously, it will need to be retuned. The best bet is to put it on the dyno and tune it.
We have done a TON of these. I actually have a few in the shop now that we are doing. If you have any questions or need any help, don't hesitate to give me a call anytime.
Eddie
615-216-7449 shop
504-416-3607 cell
Eddie, you never cease to amaze me. You are a value to this site.
11-27-2013 | 10:31 AM
#27
Registered
Joined: Oct 2010
Posts: 1,621
Likes: 402
From: Cheboygan, MI
IMO, there are several things that should be done if you want it to live a long life and run to its potential.
First, you should change the head gaskets to Cometics. If you are going to run over about 3 psi, then the exhaust valves should be changed to something like Manley's Inconel valves. You will also need to upgrade the fuel system. Take the Procharger regulator and throw it in the garbage. Use a standard 1:1 boost referenced regulator, like an Aeromotive. I would replace not only the fuel filter head to a larger one, but also the fuel lines and the pickup in the tank if it isn't large enough.(most are not large enough in production type boats) The fuel return should go back to the fuel tank. If the engine has over 200-250 hours, you should freshen up the heads. You will need to turn it a little harder than the stock 5050 rpm to take full advantage of the power. At 5 psi of boost, it will pull to about 5300 rpm.
Depending on the year of the 502 mags, there were 3 different versions of the fuel rails. The pre 99 versions have a few issues. The supply hole to the #7 injector needs to be opened up in a mill. Also, the rail should be fed fuel from both ends so that one end isn't run dry. There are quite a few other mods that needs to be done to the rail in order to make it really work correctly. The 99 and up rail needs less mods. It still should be fed from both ends, but it is already threaded for 1/4" NPT, so it's much easier to do.
With 5 psi boost, you should be in the 625 hp area. The stock injectors are good to about 650 hp without killing them by running them to hard. You can make more than 650, but it takes its toll on the injectors. If you have a pre 99 fuel rail, then you will have the Keihin injectors. There are no drop in replacements that are larger than the stockers. You can install larger injectors but it requires drilling out both the intake and the rails. If you have a 99 and up, they use the shorty injectors, so they can be replaced with larger ones if you want to make more power.
The other thing that must be addressed in the ecm. Obviously, it will need to be retuned. The best bet is to put it on the dyno and tune it.
We have done a TON of these. I actually have a few in the shop now that we are doing. If you have any questions or need any help, don't hesitate to give me a call anytime.
Eddie
615-216-7449 shop
504-416-3607 cell
First, you should change the head gaskets to Cometics. If you are going to run over about 3 psi, then the exhaust valves should be changed to something like Manley's Inconel valves. You will also need to upgrade the fuel system. Take the Procharger regulator and throw it in the garbage. Use a standard 1:1 boost referenced regulator, like an Aeromotive. I would replace not only the fuel filter head to a larger one, but also the fuel lines and the pickup in the tank if it isn't large enough.(most are not large enough in production type boats) The fuel return should go back to the fuel tank. If the engine has over 200-250 hours, you should freshen up the heads. You will need to turn it a little harder than the stock 5050 rpm to take full advantage of the power. At 5 psi of boost, it will pull to about 5300 rpm.
Depending on the year of the 502 mags, there were 3 different versions of the fuel rails. The pre 99 versions have a few issues. The supply hole to the #7 injector needs to be opened up in a mill. Also, the rail should be fed fuel from both ends so that one end isn't run dry. There are quite a few other mods that needs to be done to the rail in order to make it really work correctly. The 99 and up rail needs less mods. It still should be fed from both ends, but it is already threaded for 1/4" NPT, so it's much easier to do.
With 5 psi boost, you should be in the 625 hp area. The stock injectors are good to about 650 hp without killing them by running them to hard. You can make more than 650, but it takes its toll on the injectors. If you have a pre 99 fuel rail, then you will have the Keihin injectors. There are no drop in replacements that are larger than the stockers. You can install larger injectors but it requires drilling out both the intake and the rails. If you have a 99 and up, they use the shorty injectors, so they can be replaced with larger ones if you want to make more power.
The other thing that must be addressed in the ecm. Obviously, it will need to be retuned. The best bet is to put it on the dyno and tune it.
We have done a TON of these. I actually have a few in the shop now that we are doing. If you have any questions or need any help, don't hesitate to give me a call anytime.
Eddie
615-216-7449 shop
504-416-3607 cell
11-27-2013 | 11:18 PM
#29
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Joined: Jan 2004
Posts: 4,480
Likes: 43
From: Tennessee
11-28-2013 | 10:34 AM
#30
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Joined: Jan 2002
Posts: 4,612
Likes: 7
From: ALTO, MI
Eddie - thanks for the info.
I am planning on adding a Procharger to my Modified 509 in the near future and was planning on running E85 with an aftermarket FI system. ( FAST ) My engine is already putting out 650+ HP at 10 to 1 comp.
With the E85 I feel it should be safe to run 5 to 7 PSI boost Even with the high comp ratio.
If $ permit then next year I will build a new 598 long block to produce 1300+ HP.
This will be a BIG jump for me.
It is me first jump into the CAT world.
In the past ALL of my engines have been NA..
What are your thoughts.
Haxby has also given his input.
Thanks to everyone.
Steve
I am planning on adding a Procharger to my Modified 509 in the near future and was planning on running E85 with an aftermarket FI system. ( FAST ) My engine is already putting out 650+ HP at 10 to 1 comp.
With the E85 I feel it should be safe to run 5 to 7 PSI boost Even with the high comp ratio.
If $ permit then next year I will build a new 598 long block to produce 1300+ HP.
This will be a BIG jump for me.
It is me first jump into the CAT world.
In the past ALL of my engines have been NA..
What are your thoughts.
Haxby has also given his input.
Thanks to everyone.
Steve
