Since this is my first experience with a 502, I thought I would get some input from the experts on here. Had a mis fortune last year with a 502MPI, severely damaged the crank, 2 rods and 2 pistons. The block was bored .030, had all sorts of performance goodies. My question is , will the 502 block usually handle a .060" overbore? I will have it sonic tested before the rebuild, but that costs 100.00. I will not bother if the general consensus is that .030 is usually about the max. Since I will need a new crank, full set of rods, and pistons plus all the machine work, bearings, seals and rings, every dollar spent pushes the decision toward a complete shortblock alternative. I should mention that there is some slight scoring in 2 cylinders, and since I would be fitting new pistons, that is why I would need the overbore. I would rather do the rebuild, since I can control clearances, ring and bearing manufacture and the balance of the components.

Will another 0.010 clean it up? 0.040 should be good

the scoring appears deeper than .005", but it is tough to tell. The other issue with .040 over pistons is that the ones I need would have to be custom made and would cost nearly twice as much as the "on hand " pistons. Since I need a new crank, a 4.250" is the same price. 4.500" pistons are .030" over in a 502, but are standard bore in a 540. 4.530" pistons, and 4.560" pistons for a 540 stroke are very common. 4.540" not so much. I am seeking JE/SRP, Arias, or even wiesco pistons in 10-1 to 10.3-1 CR in the 4.250" stroke with 6.385" rods. Need to keep the crank, rods and pistons under 3000.00 or I might as well just buy a 540 shortblock. Also the "kits" I have seen do not offer a 4.540" option. I wonder if anyone has used the "kits" in a marine app. with success. They appear to use lower end components, but come balanced(so there is that savings too).

Can you just sleve the 2 suspect bores?

That block should be fine to 4.600. I would take it to 4.530 and call it done.

unknown, but I am sure it would push the budget to the 540 shortblock.

This is an answer I am hoping to see more of lol

That block will easily go 4.600. Nothing to worry about.

To answer your cost question Scat 6.385 rods with ARP bolts $376 , Eagle 4.25" stroke crank, forged , one piece rear main seal $776, balance job $200, block machine work $600-700. I'm waiting to hear from the machinist for what size pistons I need bit SRP 4032 forged pistons are $598,, rings $121 , bearings $126, short block $2897. I need to add cleaning , deck and line hone , head work cam kit , gaskets , valves , timing chain , oil pump and maybe rocker arms.

That is pretty close to my figures, cept my machine work is gonna be around 1500(including balancing), and I want to go with a total seal ring set(220$). Just under 4000 OTD vs a Dart shortblock at around 5500delivered. I have a 741 cam, but honestly, I was not that impressed with it in the last engine and may choose something else. I did install it 2 degrees advanced and maybe that cost me some power. The high lift would have ate valve springs if the engine would have lasted long enough. I am not gonna chase MPH this go round, and want dependability, and longevity over the extra 3-5mph. Plus I have a brand new(well 8hrs now) Xdrive and really dont want to stress it too much.