Crusader 454 rescue and rebuild
 

Hi all
I have taken a project on with my brother to build a 30ft boat with twin inboards.
The boat is his side (he does glassing) and I will endeavour to get some picks up for you. I'm in charge of the technical side of things even though this is my first rodeo. He wanted to go twin jets and has source a few three stage units cheap but I came across a pair of crusader 454 with velvet drives drowned and burnt for 2500AUD and decided to buy. So now we are deciding which way to go.
https://cimg9.ibsrv.net/gimg/www.off...ad379579de.jpg
Pick up from old mate
https://cimg3.ibsrv.net/gimg/www.off...0b2efba666.jpg
In workshop located Cardup Western Australia
https://cimg9.ibsrv.net/gimg/www.off...88af579ac7.jpg
Heat exchangers should be ok Osco wet exhaust closed loop are good risers and mixers need replacing
https://cimg3.ibsrv.net/gimg/www.off...b666fe5cc2.jpg
Note oil cooler bracket(normally taced onto coolers) is only thing left.

https://cimg0.ibsrv.net/gimg/www.off...bb9cf4f601.jpg
Workshop setup
https://cimg7.ibsrv.net/gimg/www.off...e6ecaa7936.jpg
Accesories stripped. Starters alternators fuel and oil manifolds all lines wiring carbs flame arrestors U/S
https://cimg9.ibsrv.net/gimg/www.off...7a1d622ec3.jpg
Ready to discover horrors internals
https://cimg1.ibsrv.net/gimg/www.off...9155027243.jpg
Engine plates
https://cimg3.ibsrv.net/gimg/www.off...82da745975.jpg
https://cimg8.ibsrv.net/gimg/www.off...b0c0e55a07.jpg
Transmission

quite the undertaking there. just fyi one of those engines is reverse rotation

https://cimg8.ibsrv.net/gimg/www.off...6066aa816c.jpg
Seawater mixed with freshwater mixed with oil that he put down manifold
https://cimg7.ibsrv.net/gimg/www.off...fa1dee07ad.jpg
The other engine was worse
https://cimg8.ibsrv.net/gimg/www.off...314ccd9d53.jpg
both engines now soaking in diesel but has been a week and still no turn so its time to remove transmissions and sumps and pull crank to remove each one by one. So far bore damage has been minimal.

Yes I'm aware thank you. If we go jets I could build two LH engines but to keep them as is one will have to be RH. Furthermore I discovered the transmissions flip the rotation in forwards gear. So I'm assuming you would have to place these in the way you want to achieve either both props spinning towards each other or away after doing the math on what works best for the boat. In this scenario once engines are placed you cannot trail and error to see what works best as you can with more modern drivetrans I'm assuming....

Just got done shoving 3 used pistons in one of my buddies 454-350hp 1986 Crusaders . If your going to reuse that exhaust and its been in saltwater at all you will never get those long studs loose in the risers, you can try but after hours with the torch heating the. riser I never got any of the studs to turn.
Cutoff wheel and cut into the riser A 1/4 inch from the joint and bang it apart. Riser and elbows and long studs will need aftermarket replacement as only the manifold is freshwater cooled.
https://cimg8.ibsrv.net/gimg/www.off...0a382984e.jpeg
https://cimg2.ibsrv.net/gimg/www.off...547d00948.jpeg
https://cimg9.ibsrv.net/gimg/www.off...5d59df54b.jpeg
https://cimg1.ibsrv.net/gimg/www.off...ad47f48ae.jpeg
https://cimg5.ibsrv.net/gimg/www.off...1234f1c0a.jpeg

The bad piston that got us to pull the motor with 2000 hours was seconds from disaster ,Cylinder was undamaged though. Light hone and found matching like-new used pistons on Ebay .https://cimg0.ibsrv.net/gimg/www.off...adee3c150.jpeg
https://cimg9.ibsrv.net/gimg/www.off...eb5ec327f.jpeg
https://cimg9.ibsrv.net/gimg/www.off...76092c8cb.jpeg
https://cimg7.ibsrv.net/gimg/www.off...61c70143c.jpeg

Nice save
I've already split risers and mixers from exhaust and yes they were an absolute c***. Got one off conventionally and the rest with oxy and cutting off. Two snapped and one needed helicoil. Where did you buy the parts for the exhausts I've seen a few good sites but I need a comprehensive site to order everything from as this is going to need most accessories.

https://cimg0.ibsrv.net/gimg/www.off...d594398429.jpg
Gear driven Cam. Getting them up in stands tomorrow and hopfully pulling crankshafts.

https://cimg4.ibsrv.net/gimg/www.off...7142925b4a.jpg
Chain drive
https://cimg5.ibsrv.net/gimg/www.off...ca1cc2d969.jpg
Seized flexplates. Only way to remove was to remove studs and spin flywheel housing to access bolts as engines still siezed.

Man you are brave! Keep posting pics - love this stuff!