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yeah I see the rust too, but nothing like it looks. Actually fairly smooth.
I had moisture from pretty bad reversion and condensation in the manifolds that i am working on correcting also.

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does anyone have the lengths for the stock pushrods. A little hard to find it.
One site showed Intake 8.280 My current ones in the motor are 7.625

exhaust 9.252 my current is 8.625


But i don't think changing the lengths would help any because shortening them would drop the rocker, but as the pics shows, the rod cant be much shorter at all are the taper at the rod end will be in the guide.

GEN VI 502, black motors, not blue motors:

GM# 10227762 8 Rod Int, Vlv Push 7.575 in
GM# 10227763 8 Rod, Exh Vlv Push 8.525in

This is from my notes...but...that doesn't mean they are correct LOL.

Edit in: just did some checking and it looks like above is correct.

that pushrod is clearly wrong.you need longer pushrods on exhaust for sure.

What does the pattern look like when you marker the valve stem and roll the engine over ?

Well i did eyeball it to see if it looked close, but i need to do that now. Was kind of concentrating on the stud thread issue but i need to do that. Will do that in the morning and reply.

mike - i may need them for the proper angle, but if i went to longer pushrods, there would be even less threads on the stud above the trunion. Probably would barely be able to start the nut on the stud.

So I'm still trying to figure out why not enough threads sticking above the trunion when all the shops i have talked to tell me i should NOT need a longer stud-something else is not right. i am going to call Harland Sharpe tomorrow and talk to them to see if they have ever run across this issue.

Something is way out wack. Those exact 3/8 bottom-7/16 top rocker studs have been used by Merc on all the HP500's with Crane Gold Rockers.
I also used them when I upgraded the cam in a 454mag and went with roller rockers.

It looks to me like valve and spring are sitting too high. What is the installed height????

Are the valves and springs new????

Do you have the flat side side of the fulcrum facing up?????
It looks like its the round side in the pic????


BTW, I think adding roller rockers to a stock 502mpi is a waste of time and $$$.