Hustler 500efi engine tear down & Build Up
11-16-2004, 01:01 AM
#1
Hustler 500efi engine tear down & Build Up
I started my winter project on my Hustler this weekend,There was nothing wrong with them I thought ,just wanted more power and maybe blowers ?It has 180 hours on the motors since I bought the boat so I figured I will tear them down and up grade some,The usual stuff.See what I got and how much work it needs . I bought the boat with 46 hours on it , It had had Whipple's on it and lot of other stuff done to the motors before I got it. They had a problem with one motor and decided to sell the boat and put the motors back to stock as they could . So I bought the boat not knowing what was in the inside 
The boat ran well and my friends think I am crazy for tearing into the motors that where running fine 
What the hell they needed cleaning anyway I am taking pictures of the tear down ,all the stuff I am doing to them and I will dyno them when I finish them
It was not that bad pulling the motors,I spent about 4 hours taking every thing off and disconnecting stuff to pull them. The only problem was the previous owner did not use antiseze on the hatch bolts . they where galded and I bared down on them so hard I heard fiberglass crack
, So where pulling them out with the hatch on it
The boat ran well and my friends think I am crazy for tearing into the motors that where running fine What the hell they needed cleaning anyway I am taking pictures of the tear down ,all the stuff I am doing to them and I will dyno them when I finish them It was not that bad pulling the motors,I spent about 4 hours taking every thing off and disconnecting stuff to pull them. The only problem was the previous owner did not use antiseze on the hatch bolts . they where galded and I bared down on them so hard I heard fiberglass crack
, So where pulling them out with the hatch on it
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11-16-2004, 01:07 AM
#3
Re: Hustler 500efi engine tear down & Build Up
My good friend Bob has this shop and the fork lift we used . On my old Scarab Blower motor we use to take it out every year, so where use to pulling out here 
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Last edited by Strip Poker 388; 01-05-2005 at 11:57 PM.
11-16-2004, 01:12 AM
#5
Re: Hustler 500efi engine tear down & Build Up
Here is my drinking crew helping drink all my beer,expensive help
It took longer taking the crap off the motor to put it on the cradle to haul it to the house than taking the motors out.
It took longer taking the crap off the motor to put it on the cradle to haul it to the house than taking the motors out.
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11-16-2004, 01:16 AM
#7
Re: Hustler 500efi engine tear down & Build Up
Bob putting the first engine in the truck . Only one will fit with the bed cover . We used my buddy;s truck for the other one .I guess when I go dyno them I will have to take it off.
. We used my buddy;s truck for the other one .I guess when I go dyno them I will have to take it off.
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Last edited by Strip Poker 388; 01-06-2005 at 12:08 AM.
11-16-2004, 01:23 AM
#8
Re: Hustler 500efi engine tear down & Build Up
Got them to the house . The garage is getting full,I had to buy 2 more engine stands ,The Scarab blower motor is on my other stand on the other side of the Chevelle,Getting tight in there.I had to put the Camaro in the trailer.
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11-16-2004, 01:42 AM
#9
Re: Hustler 500efi engine tear down & Build Up
Man there is a bunch of crap on these motors
Some of the o rings on the plumen where stretched out, doesn't look like they where leaking though , they say there real expensive
The thermostat housing was rusting pretty good.I replaced the thermostats about 2 years ago ,still rusted in them .Injectors came out pretty easy , one did not have the clip holding it on the fuel rail . Again remember someone has been into these motors before . Its starting to show
On the back of the motor they had put some regular washers on the bolts ,rusted One of the Allen head bolts on the intake was not stainless. they where all still tight.
A few of the rocker arm Polly locks where loose. Cked all the rocker arms , the bearings in them felt good. the push rod tips did not show any galling.I noticed the intake rocker arm on 1 & 8 corners where ground for clearance for the valve cover bolt hole boss. The guild plate is touching it there also.
Some of the o rings on the plumen where stretched out, doesn't look like they where leaking though , they say there real expensive
The thermostat housing was rusting pretty good.I replaced the thermostats about 2 years ago ,still rusted in them .Injectors came out pretty easy , one did not have the clip holding it on the fuel rail . Again remember someone has been into these motors before . Its starting to show On the back of the motor they had put some regular washers on the bolts ,rusted
One of the Allen head bolts on the intake was not stainless. they where all still tight.A few of the rocker arm Polly locks where loose. Cked all the rocker arms , the bearings in them felt good. the push rod tips did not show any galling.I noticed the intake rocker arm on 1 & 8 corners where ground for clearance for the valve cover bolt hole boss. The guild plate is touching it there also.
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11-16-2004, 01:52 AM
#10
Re: Hustler 500efi engine tear down & Build Up
Intake looked good ,alittle croision, removed the heat sheild,Intake gasket did not show any signs of leakage.
The head have been ported ,looks like they did not cut on the floor of the runner in the head looks like they raised the roof some and when down into the runners. not to bad . you can see in the roof where the cutter left the ridge in the top and deeper in the corners . most people have a hard time keeping it flat there. My buddy has a flow bench , we will see if they hurt or helped it?They really dont look to bad.
The head have been ported ,looks like they did not cut on the floor of the runner in the head
looks like they raised the roof some and when down into the runners. not to bad . you can see in the roof where the cutter left the ridge in the top and deeper in the corners . most people have a hard time keeping it flat there. My buddy has a flow bench , we will see if they hurt or helped it?They really dont look to bad.
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11-16-2004, 02:02 AM
#11
Re: Hustler 500efi engine tear down & Build Up
The runners don't look to small.But they are VERY ruff!! There is a ridge left from the machining that could be smoothed out ,straighten out ,kinda like when ya do the bowl area under the valve ..
I wonder how much difference the extrude honing makes??or is it the top part thats restrictive?
I wonder how much difference the extrude honing makes??or is it the top part thats restrictive?
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11-16-2004, 02:05 AM
#12
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Re: Hustler 500efi engine tear down & Build Up
Hey Strip,
Keep us posted!! Looking good! And by the way,,,,,you have way too many toys!!!
I'm jealous.....
Keep us posted!! Looking good! And by the way,,,,,you have way too many toys!!!
I'm jealous.....
11-16-2004, 02:06 AM
#13
Re: Hustler 500efi engine tear down & Build Up
Ck this out .I was taking this Russel style swivel seal fitting off.I would think its older than the boat, Its ate up.Weird
I had the Earls on my Scarab for 5-6 years and never seen anything like this.
.I was taking this Russel style swivel seal fitting off.I would think its older than the boat, Its ate up.WeirdI had the Earls on my Scarab for 5-6 years and never seen anything like this.
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11-16-2004, 02:11 AM
#14
Re: Hustler 500efi engine tear down & Build Up
Yep this is why I dont trust anybody building motors.
2 head washes on a head bolt The bolt was the same lenth as the others, Just a screw up I guess.Would it change the tourqe on that one bolt?
2 head washes on a head bolt
The bolt was the same lenth as the others, Just a screw up I guess.Would it change the tourqe on that one bolt?
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11-16-2004, 02:23 AM
#16
Re: Hustler 500efi engine tear down & Build Up
Yep I found something , Head gasket leaking water into the combustion chamber. Doesn't look like its been leaking long. It is the felpro gasket 17048?#I did not even know it was leaking .This is where the extra bolt hole like in the dart blocks might would have helped??
There is a little rust in the top of that cylinder wall ,not bad. i don't see any other leakage even between the cylinders.
I figure I will square deck the block and if I dont change the heads surface them to make sure every thing will seal next time.
, Head gasket leaking water into the combustion chamber. Doesn't look like its been leaking long. It is the felpro gasket 17048?#I did not even know it was leaking .This is where the extra bolt hole like in the dart blocks might would have helped??There is a little rust in the top of that cylinder wall ,not bad. i don't see any other leakage even between the cylinders.
I figure I will square deck the block and if I dont change the heads surface them to make sure every thing will seal next time.
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11-16-2004, 02:29 AM
#18
Re: Hustler 500efi engine tear down & Build Up
Saw this scratch ,I can hang my finger nail on it, so it .010 deep . alteast its above the ring. Cross hatch still there, looks like its a littel close on the cross hatch??.
Plate hone it should be ready again.
Plate hone it should be ready again.
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11-16-2004, 02:38 AM
#19
Re: Hustler 500efi engine tear down & Build Up
Does any body recognize the rings??
Second ring had a space with it.I will ck piston ring gap to see where they had it.
Is this a stock 500efi piston,??
I think it is the JE blower piston, I bet the CR is down with it
I know the stock ones where JE , I have not measured the ring pack yet.It is a floating pin and spiral locks.
Thanks for some input.
Rob
Second ring had a space with it.I will ck piston ring gap to see where they had it.
Is this a stock 500efi piston,??
I think it is the JE blower piston, I bet the CR is down with it
I know the stock ones where JE , I have not measured the ring pack yet.It is a floating pin and spiral locks.
Thanks for some input.
Rob
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11-16-2004, 02:45 AM
#20
Re: Hustler 500efi engine tear down & Build Up
I have not started measuring anything yet, just seeing what i have right now.
looks like a stock hv pump .tag still on it , so that tells me they did not go into it ,debur,mic it, etc.
It does have the good oil pan and screen .The screen is welded on and has the support bracket i have already ordered the Moroso blueprinted racing oil pumps. I would rather see a tray in it,But?
looks like a stock hv pump .tag still on it , so that tells me they did not go into it ,debur,mic it, etc.
It does have the good oil pan and screen .The screen is welded on and has the support bracket i have already ordered the Moroso blueprinted racing oil pumps. I would rather see a tray in it,But?
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11-16-2004, 02:53 AM
#22
Re: Hustler 500efi engine tear down & Build Up
I pulled a rod out and the center main just to see . The rod and mains are standard ,GOOD Bearing look good a little trash ,not bad , no signs of detonation and the main cap showed no chatter.I figure I put in new rod bolts and maybe bean polish the rods ?
I'll ck the rest tomorrow .upps its already tomorrow 2.50 am .
Bearing look good a little trash ,not bad , no signs of detonation and the main cap showed no chatter.I figure I put in new rod bolts and maybe bean polish the rods ?I'll ck the rest tomorrow .upps its already tomorrow 2.50 am
.
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11-16-2004, 03:01 AM
#23
Re: Hustler 500efi engine tear down & Build Up
Originally Posted by open72
warehouse at the store??
I have rebuilt his boat motor for him there also.every thing works out in the end Its great to have good friends
Thanks Bob
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11-16-2004, 04:00 AM
#24
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Re: Hustler 500efi engine tear down & Build Up
Thanks for the pics...keep us updated.
BTW, are you goin to open up the drives too?...would love to see what you find in there.
BTW, are you goin to open up the drives too?...would love to see what you find in there.
11-16-2004, 04:02 AM
#25
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Re: Hustler 500efi engine tear down & Build Up
Rob- Great pictures. Boat/trailer look like they just rolled out of the showroom. Did you buy those engine cradles or make them? At the risk of embarrassing myself, what's the deal with that fitting on the bottom of the oil pan? Is that standard or was it added? Don't think my 800SC's have anything like that. As for the hatch bolts, I remember the previous owner of my Slingshot complaining that they always loosened up. I thought he said he changed them to Stainless which may keep them from galling. Keep the pictures coming-great stuff! Lou
11-16-2004, 05:05 AM
#26
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Re: Hustler 500efi engine tear down & Build Up
Strip
The pistons are not stock. You were right they are flat top JE that are mostly used for a blower. They have a -3cc eye. I just ran the numbers, with 119 head, 10.9 gasket, .020 in the hole, -3 on the piston, that comes to 8.45CR. You were giving up some power. Also I noted the removes the Merc Thermostat housing from the block that has the built in oil thermostat. The oil pan is not stock, but looks much better.
I am curious to see which way you go. I have two 500EFI coming out of mine next weekend. The intake does not look restrictive as everyone seems to think.
I would take a look at the cam as well. I bet a blower cam was installed. The heads look like someone did a good job cleaning them up.
I still stand by the GM head gasket. I have had problems with the 17048 sealing. The GM comes on all Merc 502's. You usually have to pry it off to get it loose.
Keep posting pictures. Please post any advice on upgrades you find.
The pistons are not stock. You were right they are flat top JE that are mostly used for a blower. They have a -3cc eye. I just ran the numbers, with 119 head, 10.9 gasket, .020 in the hole, -3 on the piston, that comes to 8.45CR. You were giving up some power. Also I noted the removes the Merc Thermostat housing from the block that has the built in oil thermostat. The oil pan is not stock, but looks much better.
I am curious to see which way you go. I have two 500EFI coming out of mine next weekend. The intake does not look restrictive as everyone seems to think.
I would take a look at the cam as well. I bet a blower cam was installed. The heads look like someone did a good job cleaning them up.
I still stand by the GM head gasket. I have had problems with the 17048 sealing. The GM comes on all Merc 502's. You usually have to pry it off to get it loose.
Keep posting pictures. Please post any advice on upgrades you find.
11-16-2004, 07:58 AM
#28
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Re: Hustler 500efi engine tear down & Build Up
Hey, looks like Bob stole one of my Towmotors. I've got one exactly like it, cept mine isn't scuffed up so much.
The rockers are usually clearanced at Merc for the bolts. I don't think that was done by the previous owners.
Extrude hone is magic. But it's expensive. If you plan to blow it, it isn't going to matter as much anyhow. For a blower motor, your main area for improvement is in the ports in the heads, and a good 3 angle valvejob.
The washers on the bolt tell me that there is some trash in the bottom of the threaded hole in the block. And that the bolt bottomed out before it clamped the head properly. And they found out too late to try to clean it out and chase the threads, so they used washers. Before you go back together, run a bottoming tap into all the holes and clean them out well. Use a good sulfur oil when you do it to make the threads all nice and pretty. Double check your hole depth with a head bolt and be sure it freely spins in to a depth of less than what you will be clamping.
Always a good idea to polish the beams, but don't remove much metal. I've seen too many that have been "polished" far enough to weaken them. And don't polish crosswise. And of course, you will need to rebalance if you polish. And resize if you use new bolts (which you should do).
Crank journals could use a good micropolish. Or ultrafine crocus cloth and lacquer thinner.
The rockers are usually clearanced at Merc for the bolts. I don't think that was done by the previous owners.
Extrude hone is magic. But it's expensive. If you plan to blow it, it isn't going to matter as much anyhow. For a blower motor, your main area for improvement is in the ports in the heads, and a good 3 angle valvejob.
The washers on the bolt tell me that there is some trash in the bottom of the threaded hole in the block. And that the bolt bottomed out before it clamped the head properly. And they found out too late to try to clean it out and chase the threads, so they used washers. Before you go back together, run a bottoming tap into all the holes and clean them out well. Use a good sulfur oil when you do it to make the threads all nice and pretty. Double check your hole depth with a head bolt and be sure it freely spins in to a depth of less than what you will be clamping.
Always a good idea to polish the beams, but don't remove much metal. I've seen too many that have been "polished" far enough to weaken them. And don't polish crosswise. And of course, you will need to rebalance if you polish. And resize if you use new bolts (which you should do).
Crank journals could use a good micropolish. Or ultrafine crocus cloth and lacquer thinner.
11-16-2004, 08:42 AM
#30
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Re: Hustler 500efi engine tear down & Build Up
Yeah. The old style gapless used a conventional top ring.
The new style uses a conventional second ring and a gapless top ring. Supposedly takes care of some cylinder bore lube problems they ran into with the old style set.
They take a different hone procedure than "usual" and recommend a 20 degree X-hatch which is what it looks like you've got from the pics. If you use the gapless, you'll need to call them and get the honing procedure. Don't just bolt on the torque plate and slam a 45 degree hatch in there...
The new style uses a conventional second ring and a gapless top ring. Supposedly takes care of some cylinder bore lube problems they ran into with the old style set.
They take a different hone procedure than "usual" and recommend a 20 degree X-hatch which is what it looks like you've got from the pics. If you use the gapless, you'll need to call them and get the honing procedure. Don't just bolt on the torque plate and slam a 45 degree hatch in there...
11-16-2004, 09:10 AM
#32
Re: Hustler 500efi engine tear down & Build Up
Originally Posted by Lmarth
Rob- Great pictures. Boat/trailer look like they just rolled out of the showroom. Did you buy those engine cradles or make them? At the risk of embarrassing myself, what's the deal with that fitting on the bottom of the oil pan? Is that standard or was it added? Don't think my 800SC's have anything like that. As for the hatch bolts, I remember the previous owner of my Slingshot complaining that they always loosened up. I thought he said he changed them to Stainless which may keep them from galling. Keep the pictures coming-great stuff! Lou
. I will take a picture of the kit I made and show you . Its pretty cool.they are stainless and the rive nut [blind nut ] is aluminum there permanent now Thanks for the Info on the boltsRob
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11-16-2004, 09:18 AM
#33
Re: Hustler 500efi engine tear down & Build Up
Originally Posted by Linster
Strip
The pistons are not stock. You were right they are flat top JE that are mostly used for a blower. They have a -3cc eye. I just ran the numbers, with 119 head, 10.9 gasket, .020 in the hole, -3 on the piston, that comes to 8.45CR. You were giving up some power. Also I noted the removes the Merc Thermostat housing from the block that has the built in oil thermostat. The oil pan is not stock, but looks much better.
I am curious to see which way you go. I have two 500EFI coming out of mine next weekend. The intake does not look restrictive as everyone seems to think.
I would take a look at the cam as well. I bet a blower cam was installed. The heads look like someone did a good job cleaning them up.
I still stand by the GM head gasket. I have had problems with the 17048 sealing. The GM comes on all Merc 502's. You usually have to pry it off to get it loose.
Keep posting pictures. Please post any advice on upgrades you find.
The pistons are not stock. You were right they are flat top JE that are mostly used for a blower. They have a -3cc eye. I just ran the numbers, with 119 head, 10.9 gasket, .020 in the hole, -3 on the piston, that comes to 8.45CR. You were giving up some power. Also I noted the removes the Merc Thermostat housing from the block that has the built in oil thermostat. The oil pan is not stock, but looks much better.
I am curious to see which way you go. I have two 500EFI coming out of mine next weekend. The intake does not look restrictive as everyone seems to think.
I would take a look at the cam as well. I bet a blower cam was installed. The heads look like someone did a good job cleaning them up.
I still stand by the GM head gasket. I have had problems with the 17048 sealing. The GM comes on all Merc 502's. You usually have to pry it off to get it loose.
Keep posting pictures. Please post any advice on upgrades you find.
Whats the deal with the thermostat housing?
It has the KE oil thermostat kit on it with the Peterson oil filter system on it[Fram 25.00 oil filters].They told me they put the stock 500efi cam back in it . ill see tonight
Thanks
Rob
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11-16-2004, 09:39 AM
#34
Re: Hustler 500efi engine tear down & Build Up
Thanks for the info, I figured I would rebalanced no matter what just to make sure it was done and like may some one just replaced one rod and didn't balance it .
I am use to running the Child's gap less rings .Haven't seen these before.Infomanic I use the Child's piston ring oil they have , had pretty good luck with them as long as the hone isn't to smooth.A long time ago on a super stock motor I had 7cfm blow by on the dyno had to re hone it to get them to seat.made 40 hp seating the rings I learned to listen and learn!!!
So the cross hatch looks close together to yall too.
The one main bearing I ck was a .oo1 I guess they wanted some extra. I have seen this before .
I really don't want to change piston out ,so I might have to put the blowers on??
I think I can clean up the runners alittle,just clean them up not change the shape may help some flow.
I got a lot of checking to do.
I am use to running the Child's gap less rings .Haven't seen these before.Infomanic I use the Child's piston ring oil they have , had pretty good luck with them as long as the hone isn't to smooth.A long time ago on a super stock motor I had 7cfm blow by on the dyno
had to re hone it to get them to seat.made 40 hp seating the rings I learned to listen and learn!!!So the cross hatch looks close together to yall too.
The one main bearing I ck was a .oo1 I guess they wanted some extra. I have seen this before .
I really don't want to change piston out ,so I might have to put the blowers on??
I think I can clean up the runners alittle,just clean them up not change the shape
may help some flow.I got a lot of checking to do.
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11-16-2004, 10:10 AM
#35
Re: Hustler 500efi engine tear down & Build Up
Hey Strip....Great Looking Boat and Motors. Now Where are the Big TiTTi*s 
I have a hard time looking at one of your posts and not seeing hot chicks doin weird things to themselves!
Maybe you could post in the uncensored section........Where You Belong.......Part 2 of the Hustler project only the magazine version
I have a hard time looking at one of your posts and not seeing hot chicks doin weird things to themselves!
Maybe you could post in the uncensored section........Where You Belong.......Part 2 of the Hustler project only the magazine version
11-16-2004, 10:10 AM
#36
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Re: Hustler 500efi engine tear down & Build Up
Strip,
You might as well put the blowers on...You have the pistons and the work you do to the runners will just make them more efficient. That head gasket leak is surprising. No detonation, low compression, fel-pro gaskets....This makes me wonder whats going on in my motor. Great shots. Good luck!
Jason
You might as well put the blowers on...You have the pistons and the work you do to the runners will just make them more efficient. That head gasket leak is surprising. No detonation, low compression, fel-pro gaskets....This makes me wonder whats going on in my motor. Great shots. Good luck!
Jason
11-16-2004, 01:41 PM
#37
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Re: Hustler 500efi engine tear down & Build Up
Strip
I have a friend of mine putting new pistons in his 500's. He has the original small pop ups that will be 8.75 CR if you need them. He will have 16 of them. The original ones use a metric low tension ring. Scroggin Dickey in Texas sells a standard tension replacement metric ring set if you go that way. Also there a set of pistons in the classified section.
I am not familiar with the Eickert oil system. I just noticed it was not the Merc stuff.
I am more than likely going to make 540 EFI's out of mine. The Whipple also looks good now. 725HP will not be friendly on the drives.
I have a friend of mine putting new pistons in his 500's. He has the original small pop ups that will be 8.75 CR if you need them. He will have 16 of them. The original ones use a metric low tension ring. Scroggin Dickey in Texas sells a standard tension replacement metric ring set if you go that way. Also there a set of pistons in the classified section.
I am not familiar with the Eickert oil system. I just noticed it was not the Merc stuff.
I am more than likely going to make 540 EFI's out of mine. The Whipple also looks good now. 725HP will not be friendly on the drives.
11-16-2004, 05:01 PM
#38
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Re: Hustler 500efi engine tear down & Build Up
Strip,
Your garage looks alot like mine, a couple merc 500's and a 70 chevelle. Boat looks great, keep us posted.
Your garage looks alot like mine, a couple merc 500's and a 70 chevelle. Boat looks great, keep us posted.
11-16-2004, 05:13 PM
#40
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Re: Hustler 500efi engine tear down & Build Up
So.........I'm not the only one who has found an
" alternative duty" for a forklift
Your right........it takes more time getting all the
stuff bolted to them off, than it does to get em out.
How are the lifters ?
I'm right in the middle of doing a pair of HP500's,
that had a lifter failure ( broken roller ), so, these pictures
kind of hit close to home.
Keep the pic's coming.......It's going to be a loooong winter up here.
jt
" alternative duty" for a forklift
Your right........it takes more time getting all the
stuff bolted to them off, than it does to get em out.
How are the lifters ?
I'm right in the middle of doing a pair of HP500's,
that had a lifter failure ( broken roller ), so, these pictures
kind of hit close to home.
Keep the pic's coming.......It's going to be a loooong winter up here.
jt
