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-   -   Hustler 500efi engine tear down & Build Up (https://www.offshoreonly.com/forums/general-q/90540-hustler-500efi-engine-tear-down-build-up.html)

Strip Poker 388 04-19-2009 12:15 AM

5 Attachment(s)
oring held at 7lbs,at 8ish it needs some sealer.it holds now, sure would be nice if we could put some bolts in that blank area,

Distributor corrosion sux,

dull valve covers,there the worst and first to go,they stay polished about half the season,then ya pull em,salt water spots ,ya have to get the water off as soon as its splashed

Strip Poker 388 04-19-2009 12:18 AM

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waterspots

Strip Poker 388 04-19-2009 12:23 AM

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just picks

Strip Poker 388 04-19-2009 12:29 AM

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innercooler orings,viton,I had a hard tome finding em
exhoust gaskets ok,draing pump,dull blower.

Strip Poker 388 04-19-2009 12:34 AM

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500efi rats nest,puke tanks after 64hours,08.exhaust valves

Strip Poker 388 04-19-2009 12:39 AM

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cramped garage,still has residue from plasitgage,opps.rear main good

Strip Poker 388 04-19-2009 12:45 AM

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norm top of rod,plastigage:rolleyes:

last 2 picks shows the diff in the H and the HN rods,I dont like them being narrower.but its a stock crank,H might be better but im beating it somethimes

Strip Poker 388 04-19-2009 12:58 AM

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Steering disassembled replacing all bushing,and plastic bushions,flat washers/spacersmake it like new and tight.also reploish :drink:

I hate the tensioner,its a SOB to polish

I ground down the factory bracket,it pinches the water inlet hose at this point,it help a little

the 4 Allen heads are the top pulley blower bolts,metric,with them snug you can feel slack in the bolt holes,I don't feel good about them,needs some arp with a wide head flange.Maybe even a dowel pin to locate it better,look at the bolts on a roots style blower,Maybe its not much stress on the?

Strip Poker 388 04-19-2009 01:06 AM

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New arp crank bolt,also change the allen head intake bolts,narrow head,got arp 12pt,wide head,loctite.

Hustler hull side thicknes,orange,and bottom

Strip Poker 388 04-19-2009 01:16 AM

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cockpit inner side interior panel,cut out for speaker,went thru some blades:rolleyes:yellow fiber

Whipple bypass valve, look at your diaphragm Ive been thru 3,they bust easy,

I cleaned up the wiring,nothing else to cut out of it

alt wire

Strip Poker 388 04-19-2009 01:22 AM

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fuel pump relay
had to use a right angle drill to prime it,blower in the way:drink:

Strip Poker 388 04-19-2009 01:29 AM

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puke tank guts,oil stuff

Strip Poker 388 04-19-2009 01:34 AM

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oil drain kit,computer plugs,greased up dist,water restrictor was good,

Strip Poker 388 04-19-2009 01:42 AM

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intake polished,Distributor corrosion , Why?

Strip Poker 388 04-19-2009 01:53 AM

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Teague water pickup,very impressive piece, they said they cant make it short enough ,this is giving me fits, the Imco pickup wasn't picking up enough.Has to be a way to build/modify ,tighter radius's,I only need about 3/4 of adjustment, any suggestions or help would be greatly appreciated!!

Rob:drink:




.

upstate31sonic 04-22-2009 08:50 PM


Originally Posted by Strip Poker 388 (Post 2847370)
intake polished,Distributor corrosion , Why?

My distributors looked about the same.. Any ideas to keep that from happening?:drink:

Strip Poker 388 04-23-2009 12:24 PM


Originally Posted by upstate31sonic (Post 2850557)
My distributors looked about the same.. Any ideas to keep that from happening?:drink:

Paint didnt work,I coated it with the dia grease,I have not heard of anything else

Elite Marine 04-23-2009 01:31 PM


Originally Posted by Strip Poker 388 (Post 2847370)
Distributor corrosion , Why?

Always!!! Drives me crazy!

NoQuarter 04-23-2009 01:51 PM

Rob,

What an amazing thread. I've spent about two hours on this. Awesome!

Thx and nice work!

Tom

Strip Poker 388 04-23-2009 05:41 PM


Originally Posted by Scarab22-1998 (Post 2851142)
Rob,

What an amazing thread. I've spent about two hours on this. Awesome!

Thx and nice work!

Tom


I apprecitate it Tom. Im not very literate but I guess people get the gist of it.Its fun seeing spell ck smoke:drink:

Rob:ernaehrung004:

90mphRAGE 04-23-2009 08:04 PM


Originally Posted by Strip Poker 388 (Post 2851355)
I apprecitate it Tom. Im not very literate but I guess people get the gist of it.Its fun seeing spell ck smoke:drink:

Rob:ernaehrung004:

We don't care if your spell check smokes, just your boat, & your girls. Thanks for the info/suggestions for my build.

Thanks Rob,
Randy, from WAY inland

Strip Poker 388 05-17-2009 02:31 PM

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Thanks Randy

Well the motors have been ready since Feb :( waiting since Dec1st on painter.so Ive been plioshing everything,The transom asymembly is NEW and ready ,even polished all of it and waxed it,the trim ram shafts polished stainless ,makes it move smoother :rolleyes: rams buffed and waxed ,the tabs buffed and waxed,Steering rebuild and polished,drives are polished and new guts $$$and I have to fix the Bravo shop rebuild damage,leading edge and sides,Also I have the interror out and sent it back to Mcleod for new skins,Im having trouble with them now :(

90mphRAGE 05-22-2009 01:18 AM

I know the feeling. Weather here is tits & I'm ichin BAD to get out. Just to scratch the itch a little, I spent a the weekend detailing, waxing. Even parts you can't see. I just need to spend time with my girl. These people have NO sense of urgency, just get to it when they feel like. It's all the same to them. They haven't even begun to re-assemble the motor, don't yet have any of the top end parts. Block, pistons(big & shiny!) & crank are all on a table. Did you see the detail in the rods? Laser etched Mercury Racing in case you ever want to show off internal engine parts! Also had to cancel the Houseboat week at Lake Powell. That nearly induced a shooting rampage!!! If it's not done soon, you may see my wanted picture in the papers!
DAMN THESE SHOPS!!!!!!

Nordicflame 05-22-2009 07:32 AM

I know the feeling Randy...
Mine is back together but the hatch wouldn't fit. It's down at Arko in Springville for hatch mods and won't be done til next week :mad:

What shop is dragging a$$?

Hey Rob, you probably know but Jason's Slingshot is packing the ICs chuck full of water with a single Teague angle mounted. Doesn't seem to cause him much drag as he's easily eclipsing the century mark at 3/4 throttle (75%TPS) Not to mention that this is at 5000 feet:eek:

Dave

Strip Poker 388 05-22-2009 01:56 PM


Originally Posted by Nordicflame (Post 2871094)
I know the feeling Randy...
Mine is back together but the hatch wouldn't fit. It's down at Arko in Springville for hatch mods and won't be done til next week :mad:

What shop is dragging a$$?

Hey Rob, you probably know but Jason's Slingshot is packing the ICs chuck full of water with a single Teague angle mounted. Doesn't seem to cause him much drag as he's easily eclipsing the century mark at 3/4 throttle (75%TPS) Not to mention that this is at 5000 feet:eek:

Dave

Dave I just sent Jason my water pressure tester kit,maybe he can get a idea on the pressure? Ive been still trying to reengineer the same pick up,I ordered the lower j looking tube in a 1.5 radius there saying it will tighten it up, they said 1in I'm hoping for 1/2,with Jason saying he could cut his again a 1/2 ill be able to mount it closer to straight up.Jason's boat sounds like it going to run a good #.Thats a lot of power also:drink::drink:


90mphRAGE I know the feeling, they wait till there ready to assemble and now there waiting on parts,its like its there first build,Same as them painting my boat ,its been there 6 months and he should know all the materials and paint he needs,he painted the side and still went back for more clear ,there supposed to paint the Deck he was making a comment that Oyea I need to order more paint:eek:When I tear down I already have parts coming,by the time its ready to go back,I have the stuff I forgot:rolleyes:,little stuff makes the longer time setbacks,There is no excuse for a pro engine builder ,but from all the shops Ive been to its the norm,All of them!!!

Rob:ernaehrung004:

90mphRAGE 05-22-2009 10:50 PM

Dragging a$$
 

Originally Posted by Nordicflame (Post 2871094)
I know the feeling Randy...
Mine is back together but the hatch wouldn't fit. It's down at Arko in Springville for hatch mods and won't be done til next week :mad:

What shop is dragging a$$?

Hey Rob, you probably know but Jason's Slingshot is packing the ICs chuck full of water with a single Teague angle mounted. Doesn't seem to cause him much drag as he's easily eclipsing the century mark at 3/4 throttle (75%TPS) Not to mention that this is at 5000 feet:eek:

Dave

Wide Open Performance in Sandy seems to have more important projects like their own dragsters. I grew up with these guys & they build some *****in stuff. I thought I could trust them & they would give me a decent deal in a timely manner. The block was in the machine shop for 3 1/2 weeks, & since it's return has sat for 2 more weeks. They knew they needed the top end & could have had that on the way while the machinist did his thing. They haven't even ordered it yet! It's ridiculous. This is why doing business with friends results in a loss of friends. Problem is now, it's in pieces at the shop & I can hardly take it somewhere else. I should have used your guys from the get go. Going on 3 months now. Now they're wanting $2k more than my quote from Pfaff for heads. If I'd have known it was going to be such a hassle, I would have gathered all the parts myself, after all I spent many nights on this forum researching & know exactly what parts I need. Summers are short in Utah & the snow will be falling before we know it.

90mphRAGE 05-27-2009 09:22 PM

Stock heads?
 
Hey Rob,
Correct me if I'm wrong, but you used the stock heads with some work & the stock cam to get you those huge torque #'s. I was planing on Dart Pro-1 but I'm running out of time & $. Heads are out for a valve job, springs & some port polishing. Just wondering if this will work good for me. If I had any patience, my shop is getting set up for cryo treating & I would have them do some parts. They will be the only in Utah. This would put me back another month. Summer's too short. Also, did you do anything special w/ lifters or rockers? I'm more concerned with getting out than setting records.

Strip Poker 388 05-28-2009 12:36 AM


Originally Posted by 90mphRAGE (Post 2874508)
Hey Rob,
Correct me if I'm wrong, but you used the stock heads with some work & the stock cam to get you those huge torque #'s. I was planing on Dart Pro-1 but I'm running out of time & $. Heads are out for a valve job, springs & some port polishing. Just wondering if this will work good for me. If I had any patience, my shop is getting set up for cryo treating & I would have them do some parts. They will be the only in Utah. This would put me back another month. Summer's too short. Also, did you do anything special w/ lifters or rockers? I'm more concerned with getting out than setting records.


yes stock500efi heads,I worked the bowl,cc ed the chambers,deshrouded and mirror polished them, the good and black now:drink:guides,didn't move much on the intake side,port match to the Whipple,exhaust I did more to it,really its a waste of time if I had the money at the time could of bout some iron eagles or better,no cyro spend the money on the heads,I used a crane 741, not the best for blowers,it has more over lap.some said the stock cam would build more power,to me it was 50/50,I'm sure the bigger cam let me buz it high making more power,on he dyno after 9lbs the increasement of hp climbed slower,ruining out of head and cam.RM builder has one better that the 741,ill change to it if I change cams,Comp cams make the same cam specks as the 741,I bought new crane rockers,should of reused the old ones,I would change the crane lifters,[depending on hours] comp makes a short version,requir push rods,RM builder has the stock height,the a high quality morel,Isky makes a GOOD lifter,red zone,they also have a better spring than the comp 929. Its good insurance,remember valve train is the week link in most motors,

Rob

Linster 05-28-2009 04:42 AM

Been away from this area for a while. Glad to see you are keeping things in order. That is an awesome amount of work you are doing. Thanks for the pictures. I probally need to do all that to mine next year.

Nordicflame 05-28-2009 08:07 AM

Hey Linnie, Just stick those new blowers on there and make that hatch fit :drink:
(my hatch is out being modified; I'll shoot you some pics when I pick it up)

Randy,
Rob's spot on with RM Builder; He will spec grind any cam you want for your application. Again, hopefully you have someone to handle the ECU issue with any changes in cam and heads.
The blower has a way of over riding marginal heads :) Go have fun!
Also, as far as cryo treating, your guys will be the second in Utah :rolleyes:

Dave

Strip Poker 388 05-28-2009 04:37 PM


Originally Posted by Linster (Post 2874631)
Been away from this area for a while. Glad to see you are keeping things in order. That is an awesome amount of work you are doing. Thanks for the pictures. I prob ally need to do all that to mine next year.



Thanks Linnie,and are your blower on it yet? I'll send ya some of my extra energy,get after it bro:ernaehrung004:
Rob

Linster 05-29-2009 09:17 AM

Not yet, waiting on seeing Dave's hatch modification. I will need to do the same. Will happen this fall now, unless it keeps raining. Might start in August after all the trips are done. Keep up the good work.

Strip Poker 388 05-29-2009 01:09 PM


Originally Posted by Linster (Post 2875635)
Not yet, waiting on seeing Dave's hatch modification. I will need to do the same. Will happen this fall now, unless it keeps raining. Might start in August after all the trips are done. Keep up the good work.

ya no ya will like the whine:ernaehrung004:
[YOUTUBE]http://www.youtube.com/watch?v=W9KsgFjI7ak[/YOUTUBE]

Uncle Dave 05-29-2009 07:35 PM

Sweet.

UD

90mphRAGE 05-29-2009 08:49 PM


Originally Posted by Nordicflame (Post 2874725)
Hey Linnie, Just stick those new blowers on there and make that hatch fit :drink:
(my hatch is out being modified; I'll shoot you some pics when I pick it up)

Randy,
Rob's spot on with RM Builder; He will spec grind any cam you want for your application. Again, hopefully you have someone to handle the ECU issue with any changes in cam and heads.
The blower has a way of over riding marginal heads :) Go have fun!
Also, as far as cryo treating, your guys will be the second in Utah :rolleyes:

Dave

Thanks for the advise guys. I decided to do a little work to the stock heads, new moving parts & just replace the stock cam. I want to stay away from programming if I can help it & keep a reliable 90ish top end. That's the safe speed in a 25' with all the other maniacs on the waverunners around here anyway. Besides, I don't need to get into the drive anytime soon. Hope my next boat is a Thor, then I'll go crazy. I'm not the fastest boat around here, but maybe fastest 25?

90mphRAGE 06-26-2009 08:28 PM

The time has come!
 
Thanks Rob & everyone else on this post. This site is the best place for advise & experience for us powerboaters. My boat is finally ready to lake test this weekend. Just in time for good weather & rising gas prices. Wide Open Performance came through. Once all the parts arrived, it went very quick & they did an awsome job. Break in this weekend & hammer down for the 4th @ Starvation! If I get close to Robs #'s, should be 85+mph @ my altitude.

Strip Poker 388 09-01-2009 06:05 PM


Originally Posted by 90mphRAGE (Post 2897744)
Thanks Rob & everyone else on this post. This site is the best place for advise & experience for us powerboaters. My boat is finally ready to lake test this weekend. Just in time for good weather & rising gas prices. Wide Open Performance came through. Once all the parts arrived, it went very quick & they did an awsome job. Break in this weekend & hammer down for the 4th @ Starvation! If I get close to Robs #'s, should be 85+mph @ my altitude.


Up date us Randy????:drink:

90mphRAGE 09-12-2009 10:30 PM

Been burnin up the lakes for a couple months now. 85 gps @ Powell. Minor issue w/ TPS connection. All is good, but now it's about time to put it in storage. Gotta move somewhere warm. Planning desert storm in the spring to see what she'll run at low elev.

Strip Poker 388 10-17-2009 03:29 PM

2 Attachment(s)
Ive had a few people interested in the valve cover fitting.They make it in #12 and 16,The fitting on the inside has holes drilled in it.kinda like a baffle.They list it for vacuum pumps.It makes a nice fitting run the #12 hose to the puke tank.Theres no leaking on the valve cover,no oil residue anywhere.The hole diameter is the same as the grommets and PVC valve hole,that works out good.:drink:

The part # is 22635 Moroso.

http://www.moroso.com/catalog/catego...?catcode=13635


<a href="http://videos.streetfire.net/video/Hustler-dyno-pull-911hp_70275.htm"><img src="http://px5.sfstatic.com/thumbs/0000/20/57/70275.jpg"/><br>Hustler dyno pull 911hp 11.5 lbs,Whipple</a>

littledcsrodshop 10-17-2009 07:26 PM

The motors look nice Rob !! I like how the fp's & filter mount to the pan that way.. The brackets may be common (?) but for some reason thats the first time I've ever seen that or payed enuff attention but either way I may have to steal that idea..


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