Table of Contents

Chapter 1: Engine Blocks 7
Small-Blocks 7
Big-Blocks 11
Engine Block Filler 13
Lifter Bore Bank Angles 14
Engine Block Machining 14
Bottom-End Girdles 17

Chapter 2: Crankshafts 20
Factory Small-Block Crank Identification and Application 20
Factory Big-Block Crank Identification and Application 20
Aftermarket Crankshafts 23
Bearing Clearance 24
Crank Grinding 26
Stroking 30
Magnafluxing 30
Engine Bearings 31
Anti-Friction Coatings 32
Crankshaft Balancing 33
Harmonic Balancers 35
Rear Main Bearing Seals 38

Chapter 3: Camshafts and Valvetrain 39
Rocker Arms 39
Pushrods 44
Timing Chains 45
Roller-Bearing Cam Bolt and Camshaft Walk 46
Camshafts and Camshaft Selection 47
Camshaft Specifications 51
Lifters 51
Valvesprings, Retainers and Locks 53

Chapter 4: Connecting Rods 56
Factory Connecting Rods 56
Aftermarket Steel Connecting Rods 58
Aluminum Connecting Rods 59
Connecting-Rod Side Clearance 60
Rod-to-Stroke Ratio 61

Chapter 5: Pistons, Rings and Pins 62
Factory Cast Pistons 62
Aftermarket Forged Pistons 64
Off-the-Shelf Pistons 64
Custom Pistons 65
Piston Domes and Compression Ratio 66
Piston Rings 68
Gapless Rings 70
Piston Clearances 71
Piston Pins 71
Coatings 75
Ring Gaps 76

Chapter 6: Oiling System 78
Oiling-System Flow Path 78
Oil Restrictors 80
Main-Bearing Modifications 81
Lifter Gallery Plugs 81
Oil Pumps 82
Oil-Filter Adapters and Oil Filters 84
Oil Pans 85
Windage Trays 87
Engine Oils 87
Vacuum Pumps 88

Chapter 7: Cylinder Heads and Induction 90
Factory Small-Block Cylinder Heads 90
Factory Big-Block Cylinder Heads 91
Head Gaskets 92
The Milling Process 94
Aftermarket Cylinder Heads 95
Porting Tips and Tricks 102
Valveguides 106
The Valve Job 107
The Flow Bench 109
CNC-Ported Cylinder Heads 110
Valves 111
Intake Manifolds 113
Carburetors 122

Chapter 8: Exhaust System 127
Factory Cast-Iron Manifolds 127
Center Divider on Factory Heads 129
Header Sizing 130
Full-Size Headers 131
Low-Cost Headers 131
Merge Collectors 131
Painted versus Coated versus Stainless 132
Crank Case Evacuation 132
Exhaust Gaskets 132
Mufflers and Exhaust Pipes 133

Chapter 9: Ignition System 134
Ignition Boxes 134
Advance Curves 136
Crank Triggers and Magnetic Pickups 136
Distributors 136
Distributor Gears 137
Ignition Coils 138
Spark Plugs 138
Spark Plug Wires 139
Setting Ignition Timing 139

Appendix A: Assembly Tips and Techniques 140
Appendix B: Popular BTR Performance Combinations 142
Source Guide 143